Aerosol generating article comprising a plug element containing a coated or impregnated paper material

Abstract

The aerosol generating article comprises an aerosol generating substrate and a downstream element provided downstream of the aerosol generating substrate and axially aligned with the aerosol generating substrate. The downstream element includes a plug element. The plug element includes a cellulosic filter material. The cellulosic filter material includes a paper material and an additive coating applied to the paper material. The additive coating includes at least one exogenous polysaccharide and at least one additive for reducing phenols. The exogenous polysaccharide includes acetylated starch or oxidized and slightly acetylated starch. The plug element contains at least 5 weight percent of acetylated starch or oxidized and slightly acetylated starch on a dry weight basis, based on the dry weight of the paper material.

Description

Technical Field

[0001] The present invention relates to an aerosol generating article comprising at least one element formed from a biodegradable filter material. In particular, the present invention relates to an aerosol generating article comprising a downstream element located downstream of and axially aligned with an aerosol generating substrate, the downstream element comprising a plug element formed from a biodegradable cellulose-based filter material.

Background Art

[0002] Conventional aerosol generating articles such as filter cigarettes typically comprise a cylindrical rod of tobacco cut filler surrounded by a paper wrapper and a cylindrical filter axially aligned with the rolled tobacco rod, most often with ends abutting. The cylindrical filter typically comprises one or more plug elements of a fibrous filter material such as cellulose acetate tow surrounded by a paper plug wrap. Conventionally, the rolled tobacco rod and filter are joined by a tipping wrapper band formed from a generally opaque paper material surrounding the entire length of the filter and an adjacent portion of the rolled tobacco rod. In well-known filter cigarettes, the filter is typically adapted for the removal of particulate and gaseous components of the mainstream smoke.

[0003] Numerous aerosol-generating articles in which tobacco is heated rather than burned have also been proposed in the art. In heated aerosol-generating articles, aerosols are generated by heating an aerosol-generating substrate, such as tobacco. Known heated aerosol-generating articles include, for example, smoking articles in which aerosols are generated by electric heating or by heat transfer from a combustible fuel element or heat source to an aerosol-generating substrate. During smoking, volatile compounds are released from the aerosol-generating substrate by heat transfer from the heat source and are carried into the air drawn through the smoking article. As the released compounds cool, they condense to form an aerosol, which is inhaled by the consumer. Many known heated aerosol-generating articles comprise one or more elements formed of fibrous filter material.

[0004] After an aerosol-generating article is smoked and discarded, it is desirable that its components, particularly any elements formed from fibrous filter material, be destroyed as quickly as possible. However, cellulose acetate, the most commonly used fibrous filter material in aerosol-generating articles, is not biodegradable and can persist in the environment for many years. As a result, used cigarette filters made from cellulose acetate tend to accumulate in the environment and are one of the most commonly recovered plastic products in beach cleanup activities. Therefore, it is desirable to provide more sustainable cellulose acetate alternatives for manufacturing aerosol-generating article components, particularly filter or mouthpiece components.

[0005] To address the environmental impact caused by the direct disposal of post-consumer waste containing non-biodegradable plastics into the environment, some jurisdictions have introduced legislation banning single-use plastic products (SUPs). The term SUP refers to a product that is manufactured whole or partially from plastic and is typically intended for single use or short-term use before being discarded. Therefore, it is generally desirable to replace single-use plastics in aerosol-generating articles with natural, biodegradable alternatives.

[0006] A wide variety of alternative materials have already been proposed for use as filtration materials for aerosol-generating articles. However, in many cases, these alternative filtration materials have been found to fail to provide consumers with an acceptable filtration efficiency and smoking experience.

[0007] For example, filters made from cellulose pulp or paper material have been known for nearly a century, as evidenced by GB 433048 A. Several processes for manufacturing paper filters have been disclosed over the years, including those described in US 3238852 A. However, consumers have frequently reported that paper filters have an undesirable effect on the flavor of smoke or aerosol. This so-called “paper taste” has been described as being associated with a rougher, drier sensation compared to the sensation provided by known smoking articles with filters formed from cellulose acetate.

[0008] In other cases, these alternative filtration materials have been found to be insufficient in terms of hardness and processability. Furthermore, in many cases, dispersible and biodegradable materials have been found to be unsuitable for use in existing manufacturing processes, and their use would require excessively large modifications to existing methods and equipment to make them commercially viable.

[0009] Therefore, it is desirable to provide an aerosol generating article having components that are formed from at least partially biodegradable filter material and provide filtration efficiency equivalent to that of cellulose acetate tow. In particular, it is desirable that the components be formed from biodegradable filter material that can still effectively reduce or remove undesirable compounds from aerosols generated from a substrate (e.g., phenol).

[0010] Furthermore, it is desirable to provide such aerosol-generating articles that give consumers an acceptable sensory experience. In particular, it is desirable that the components be made of biodegradable filter materials that have little to no effect on the taste perceived by consumers during the use of the aerosol-generating article and generally do not adversely affect the smoking experience.

[0011] Furthermore, it would be desirable to provide such aerosol-generating articles that are less likely to produce smoke or aerosols that give consumers a rough, dry feeling. For example, it would be desirable to provide aerosol-generating articles that include elements containing paper materials that reduce or completely eliminate the "paper taste."

[0012] In other words, it is desirable to provide such aerosol generating articles that provide smoke or aerosols having a taste profile equivalent to that of existing cellulose acetate filtered aerosol generating articles, without bias towards the inherent taste variability associated with different types of aerosol generating substrates.

[0013] Furthermore, it is desirable to provide such aerosol-generating articles that can be easily manufactured using existing high-speed manufacturing techniques and equipment that requires only minimal modifications.

[0014] Furthermore, it is desirable that the filtration material be effectively formed into components that provide a consumer-acceptable appearance and feel. For example, it is desirable that the filtration material be effectively formed into components of an aerosol-generating article that provide a desirable density, hardness, and draw-to-discharge (RTD). [Overview of the Initiative]

[0015] This disclosure relates to an aerosol generating article. The aerosol generating article may comprise an aerosol generating substrate. Furthermore, the aerosol generating article may comprise a downstream element. The downstream element may be provided downstream of the aerosol generating substrate. The downstream element may be provided axially aligned with the aerosol generating substrate.

[0016] The downstream element may include a plug element. The plug element may contain a cellulose-based filter material. The cellulose-based filter material may include a paper material. The cellulose-based filter material may also contain an additive coating applied to the paper material.

[0017] The additive coating may contain at least one exogenous polysaccharide.

[0018] The additive coating may include at least one additive for reducing phenol.

[0019] The plug element may contain at least 5 weight percent of at least one exogenous polysaccharide based on the dry weight of the paper material on a dry weight basis.

[0020] According to a first aspect of the present invention, an aerosol generating article is provided comprising an aerosol generating substrate and a downstream element provided downstream of the aerosol generating substrate and axially aligned with the aerosol generating substrate. The downstream element includes a plug element. The plug element includes a cellulosic filter material comprising a paper material and an additive coating applied to the paper material. The additive coating comprises at least one exogenous polysaccharide and at least one additive for reducing phenols. The plug element contains at least 5 weight percent of at least one exogenous polysaccharide based on the dry weight of the paper material on a dry weight basis.

[0021] In a preferred embodiment, the aerosol generating article comprises an aerosol generating substrate and a downstream element provided downstream of the aerosol generating substrate and axially aligned with the aerosol generating substrate. The downstream element includes a plug element. The plug element includes a cellulosic filter material comprising a paper material and an additive coating applied to the paper material. The additive coating comprises at least one exogenous polysaccharide and at least one additive for reducing phenol, wherein the at least one exogenous polysaccharide comprises acetylated starch or oxidized acetylated starch. The plug element contains at least 5 weight percent of acetylated starch or oxidized acetylated starch based on the dry weight of the paper material on a dry weight basis.

[0022] As used herein in connection with the present invention, the term "aerosol-generating article" is used to describe an article comprising an aerosol-generating substrate that generates and delivers a heated, inhalable aerosol to a user.

[0023] When used herein in connection with the present invention, the term "aerosol-generating substrate" is used to describe a substrate comprising an aerosol-forming material that can release an aerosol in response to heating of a volatile compound capable of generating an aerosol.

[0024] As used herein in connection with the present invention, the term "aerosol" is used to describe a dispersion of solid particles or droplets, or a combination of solid particles and droplets, in a gas. Aerosols may be visible or invisible. Aerosols may include not only vapors of substances that are normally liquid or solid at room temperature, but also solid particles or droplets of liquid, or a combination of solid particles and droplets of liquid.

[0025] When used herein in connection with the present invention, the term "aerosol generator" is used to describe a device that generates an aerosol by interacting with an aerosol-generating substrate of an aerosol-generating article.

[0026] The aerosol-generating article according to the present invention has a proximal end through which aerosol exits the aerosol-generating article for delivery to the user during use. The proximal end of the aerosol-generating article may also be referred to as the downstream end or the mouth-side end of the aerosol-generating article. During use, the user directly or indirectly inhales the proximal end of the aerosol-generating article to inhale the aerosol generated by the aerosol-generating article.

[0027] The aerosol-generating article according to the present invention has a distal end. The distal end is opposite to the proximal end. The distal end of the aerosol-generating article may also be referred to as the upstream end of the aerosol-generating article.

[0028] The components of the aerosol-generating article according to the present invention may be described as being upstream or downstream of each other based on their relative positions between the proximal end and the distal end of the aerosol-generating article.

[0029] As used herein in connection with this specification, the term "longitudinal direction" is used to describe the direction between the upstream end and the downstream end of the aerosol-generating article. During use, air is drawn through the aerosol-generating article in the longitudinal direction.

[0030] As used herein in connection with the present invention, the term "length" is used to describe the maximum dimension in the longitudinal direction of the aerosol-generating article or a component of the aerosol-generating article.

[0031] As used herein in connection with the present invention, the term "transverse direction" is used to describe a direction perpendicular to the longitudinal direction. Unless otherwise specified, the "cross-section" of the aerosol-generating article or a component of the aerosol-generating article refers to a cross-section.

[0032] As used herein in connection with the present invention, the term "width" refers to the maximum transverse dimension of an aerosol-generating article or a component of an aerosol-generating article. If the aerosol-generating article has a substantially circular cross-section, the width of the aerosol-generating article corresponds to the diameter of the aerosol-generating article. If the components of the aerosol-generating article have a substantially circular cross-section, the width of the components of the aerosol-generating article corresponds to the diameter of the components of the aerosol-generating article.

[0033] As used herein in relation to the present invention, the term "rod" is used to mean a generally cylindrical element having a substantially circular, oval, or elliptical cross-section.

[0034] As used herein in connection with the present invention, the term “hollow tubular element” is used to describe a substantially cylindrical element having a tubular space along its longitudinal axis. The tubular portion may have a substantially circular, substantially oval, or substantially elliptical cross-section. The tubular space may have a substantially circular, substantially oval, or substantially elliptical cross-section. Specifically, the term “hollow tubular element” is used to describe an element that defines at least one airflow conduit establishing an uninterrupted fluid communication between the upstream end of the hollow tubular element and the downstream end of the hollow tubular element.

[0035] Unless otherwise specified, the draw resistance (RTD) of a component or aerosol-generating article according to the present invention shall be measured in accordance with ISO 6565-2015. RTD refers to the pressure required to pump air through the entire length of the component. The terms “pressure drop” or “draw resistance” for a component or article may also refer to “resistance to draw.” These terms generally refer to measurements performed in accordance with ISO 6565-2015, which are normally carried out at a temperature of approximately 22 degrees Celsius, a pressure of approximately 101 kPa (approximately 760 Torr), and a relative humidity of approximately 60%, with a volumetric flow rate of approximately 17.5 milliliters per second at the output or downstream end of the component being measured.

[0036] The draw-out resistance (RTD) per unit length of a particular component (or element) of an aerosol generating article, such as an upstream element or aerosol generating element, can be calculated by dividing the measured draw-out resistance of the component by the total axial length of the component. RTD per unit length refers to the pressure required to force air through a unit length of the component. Throughout this disclosure, unit length refers to a length of 1 millimeter. Therefore, to derive the RTD per unit length of a particular part, a specific length of the component, for example, a 15-millimeter specimen, can be used for measurement. The RTD of such a specimen is measured according to ISO 6565-2015. For example, if the measured RTD is approximately 15 milliH2O, the RTD per unit length of the component is approximately 1 milliH2O / millimeter. The RTD per unit length of a component generally depends, in particular, on the structural properties of the material used in the component, as well as the cross-sectional shape or external shape of the component, among other factors.

[0037] The aerosol stream generated during the use of an aerosol-generating article is a complex mixture of chemicals, including semi-solid particles dispersed in a fluid matrix of vapors and permanent gases. Where used herein in connection with the present invention, the term “filtration efficiency” is used to describe the ability of an element containing a filter material to capture particulate matter contained in such aerosol streams. In practice, the term “filtration efficiency” means the proportion of overall dry particulate matter carried in the aerosol stream and retained within the element containing the filter material during use.

[0038] The term "polysaccharide" generally refers to a polysaccharide with the general formula (C6H 10 O5) nPolysaccharides refer to high molecular weight carbohydrates consisting of long chains of monosaccharide units linked by glycosidic bonds, where n typically ranges from 40 to 3000. Polysaccharides, which occur widely in nature, exhibit molecular structures that can be linear or highly branched, and may consist of multiple monosaccharides of the same monosaccharide unit (homopolysaccharide) or may contain different monosaccharide units (heteropolysaccharide). Common examples of polysaccharides found in plants include cellulose and starch. Glycogen is an example of a polysaccharide commonly found in most mammalian and non-mammalian cells. Chitin is a polysaccharide found in the exoskeleton of insects, the cell walls of fungi, and certain hard structures inverted and in fish.

[0039] As used herein in connection with the present invention, the term “exogenous polysaccharides” is used to mean polysaccharides incorporated into an additive coating that may be applied to a plug element comprising a paper material having a certain endogenous polysaccharide content.

[0040] As will be discussed in more detail below, the pulp that forms the basis of paper materials contains compounds such as cellulose and hemicellulose, which are themselves polysaccharides or mixtures of polysaccharides. Exogenous polysaccharides are supplied in isolated forms, extracted, and separated from other components of the material from which they originate (e.g., plant material). Thus, exogenous polysaccharides are supplied exogenously from any cellulose or hemicellulose derived from plant material present in the pulp that forms the basis of paper materials. In other words, the term “exogenous polysaccharides” refers to a distinct and separate source of polysaccharides for any polysaccharides that are essentially supplied within the paper material.

[0041] As used herein, the term “phenol” refers to a group of chemical compounds consisting of a hydroxyl group (-OH) directly bonded to an aromatic hydrocarbon group. Phenol groups include phenol, catechol, m+P-cresol, and o-cresol. As used herein in connection with the present invention, the term “additive for reducing phenol” is used to mean any additive that, when added to the mouthpiece of an aerosol generating article, has the ability to reduce the level of at least one of phenol, catechol, m+P-cresol, and o-cresol in the smoke or aerosol when subjected to a standard smoking test.

[0042] As used herein, the term “flue gas” is used to mean certain gaseous products produced by the combustion or thermal decomposition of an aerosol-generating substrate.

[0043] The present invention provides an improved aerosol-generating article comprising at least one downstream element, the downstream element comprising a plug element formed of a cellulosic filter material comprising a paper material and an additive coating comprising a combination of polysaccharides and additives for reducing phenols. Thus, the aerosol-generating article according to the present invention can be advantageously formed of more sustainable materials, containing reduced or zero levels of disposable plastics. In particular, the aerosol-generating article according to the present invention uses paper material instead of cellulose acetate fibers to form elements such as filter elements, thereby significantly improving the biodegradability of the aerosol-generating article.

[0044] The addition of additive coatings to paper materials has been found to be advantageous in that it significantly reduces the influence of downstream filtering materials on the taste of smoke or aerosols provided to consumers in aerosol-generating articles. In particular, the use of additive coatings containing polysaccharides in combination with additives to reduce phenol has been found to be desirable in reducing or eliminating the rough, dry sensation often referred to by consumers as the "taste of paper."

[0045] By adjusting the amount of additives to reduce at least one exogenous polysaccharide and phenol in the downstream element's filter material, it is advantageously possible to adjust the taste sensation associated with the smoke or aerosol provided by the aerosol generating article according to the present invention to closely approximate the taste profile of an aerosol generating article having substantially the same structure and composition but comprising a cellulose acetate filter instead of the downstream element according to the present invention.

[0046] Simultaneously, the addition of additive coatings to paper materials was found to significantly improve the filtration characteristics of downstream elements. In particular, the use of additive coatings containing a combination of additives and polysaccharides for phenol reduction was found to significantly improve the reduction of certain undesirable compounds from mainstream smoke or aerosols compared to the use of paper materials alone. The composition of the additive coatings can be advantageously modified to optimize the filtration efficiency of downstream elements so as to achieve the reduction of phenol and other undesirable compounds as with conventional cellulose acetate tow.

[0047] As defined above, the plug element of the downstream element of the aerosol generating article according to the present invention comprises a paper material coated with an additive coating.

[0048] For the purposes of the present invention, the term “paper material” generally means a web of cellulosic fibers in sheet form. Where used herein in connection with the present invention, the term “sheet” is used to describe a thin, plate-like element having a width and length considerably greater than its thickness. Sheets may have a thickness ranging from 0.03 to 2 millimeters and a basis weight from 10 grams / m² to 200 grams / m².

[0049] Paper and cardboard are types of paper materials suitable for manufacturing plug elements for use in aerosol-generating articles according to the present invention. The term “paper” is typically used to mean such a web of one type of cellulosic fiber in sheet form, with sheets having a thickness ranging from 0.03 to 0.20 millimeters. The term “cardboard” is typically used to mean such a web of one type of cellulosic fiber in sheet form, with sheets having a thickness ranging from 0.20 to 2 millimeters.

[0050] To form a web, the aqueous slurry of pulp fibers is discharged through a sieve-like screen onto which a mat of randomly woven fibers is placed. Water is further removed from this mat by pressurization, optionally by suction or vacuum, by heating, or both. Once the drying process is complete, a generally flat and uniform sheet of paper material is obtained.

[0051] Advantageously, using paper materials containing randomly oriented cellulose fibers facilitates the decomposition of the plug elements. This is because the randomly oriented fibers can be dispersed more easily after the plug elements are discarded, especially compared to the substantially continuous filaments of conventional cellulose acetate tow filters. Increased fiber dispersion increases the exposure of individual fibers to the environment, and therefore further increases the rate at which the plug elements decompose.

[0052] The term "pulp" is used to refer to lignocellulose fibrous material prepared by chemically or mechanically separating cellulose fibers from wood, fiber crops, waste paper, or cloth. Lignocellulose is composed primarily of cellulose, hemicellulose, and lignin.

[0053] The term "cellulose" is derived from the formula (C6H 10 O5) nThis shows organic compounds containing [specific compounds]. Polysaccharides, consisting of linear chains of hundreds to thousands of D-glucose units linked by glycosidic bonds, are structural components of the primary cell walls of green plants and many algae. The term "hemicellulose" refers to a group of polysaccharides typically found in cellulose in the cell walls of almost all terrestrial plants. Hemicellulose polysaccharides are shorter and typically branched than cellulose. From a chemical standpoint, cellulose is derived solely from glucose, while hemicellulose polysaccharides contain both five-carbon sugars (xylose and arabinose) and six-carbon sugars (mannose and galactose on top of glucose). Furthermore, acidified forms of sugars such as glucuronic acid and galactronic acid can be found in hemicellulose.

[0054] The term "lignin" refers to a group of highly heterogeneous polymers derived from several precursor lignols. This heterogeneity arises from the diversity and variability of crosslinking between these lignols. For example, the relative amounts of precursor lignols generally vary depending on the plant source. Lignin polymers typically form the main structural material in the cell walls of plant support tissues, particularly wood and bark, and are also found in red algae. Lignin fills the gaps in cell walls between cellulose, hemicellulose, and pectin components, and provides rigidity through crosslinking between lignol molecules.

[0055] Lignin is understood to inhibit the formation of hydrogen bonds between cellulose fibers. Therefore, some pulping processes are designed to remove as much lignin as possible, as this is understood to provide stronger paper by promoting interfiber bonding. Other pulping processes aim to separate the fibers instead. Pulp intended for use in fine paper typically undergoes a papermaking process that aims for both lignin removal and fiber separation.

[0056] However, regardless of the specific pulping process used, lignin becomes more resistant to removal as pulping progresses, while cellulose fibers become more vulnerable to the chemicals used, mechanical pulping, or both. Therefore, complete removal of lignin can result in excessive cellulose loss in the cellulose fibers, or undesirable degradation of the mechanical properties of the cellulose fibers, so some lignin usually remains in all paper material at the end of the papermaking process.

[0057] In the context of this invention, the term "endogenous lignin" is used to mean the residual lignin content found in paper material at the end of the papermaking process.

[0058] For example, kraft paper materials, i.e., paper or cardboard produced from pulp obtained by treating wood chips with high-temperature aqueous solutions of sodium hydroxide and sodium sulfide, have a low endogenous lignin content (less than 10 weight percent, and sometimes as low as 2 ÷ 6 weight percent). This is because, in the strong chemical pulping process to obtain pulp, the lignin molecules are broken down into smaller soluble fragments and the cellulose fibers are separated, thus removing most of the lignin. Finer paper materials may have a relatively high endogenous lignin content. For example, newspaper may often contain 18 ÷ 30 weight percent lignin.

[0059] In the context of this invention, the term “endogenous polysaccharide content” is used to mean the polysaccharide content found in the paper material at the end of the papermaking process. Generally, endogenous polysaccharide content describes the overall content of cellulose and hemicellulose in the paper material. For example, kraft paper material may contain 75 ÷ 85 weight percent cellulose and 10 ÷ 20 weight percent hemicellulose, and therefore the endogenous polysaccharide content in kraft paper material may be 85 ÷ 95 weight percent.

[0060] As used herein in connection with the present invention, the term “exogenous polysaccharides” is used to mean polysaccharides incorporated into an additive coating that can be applied to a plug element containing a paper material having a certain endogenous polysaccharide content. Exogenous polysaccharides are provided in isolated forms, extracted, separated from other components of natural materials, e.g., plant materials, and obtained therefrom. Thus, exogenous polysaccharides are provided exogenously from cellulosic or hemicellulose plant materials present in the paper material. In other words, the term “exogenous polysaccharides” refers to a distinct and separate source of polysaccharides for any polysaccharides essentially provided within the paper material.

[0061] After the application of exogenous polysaccharides to the paper material of the plug element, the "total polysaccharide content" in the plug element is understood to be the sum of a) the endogenous cellulose and hemicellulose content present in the plug element before the application of exogenous polysaccharides, and b) the amount of exogenous polysaccharides applied to the paper material.

[0062] As part of the papermaking process, fillers may be added to pulp fibers before web formation. Fillers used in the papermaking process are typically inorganic particulate matter, usually in the size range of 0.1 to 10 micrometers, that can impart specific desirable properties to the paper material. For example, fillers may affect the structure, appearance (e.g., brightness and opacity), density, tensile strength, and other measurable properties of the paper material. Examples of commonly used papermaking fillers include clay, limestone, chalk, talc, calcined stone, luthi (titanium dioxide), calcium sulfate, and amorphous silica.

[0063] The paper material used in the manufacture of the plug element of the aerosol generating article according to the present invention may contain one or more of the above-mentioned papermaking fillers.

[0064] The paper material preferably does not contain cellulose acetate fibers or any other fibers formed from non-biodegradable polymers.

[0065] In plug elements, the paper material is typically in the form of a sheet, which is assembled or otherwise processed to form a rod shape. As used herein in relation to the present invention, the term "assembled" means that the sheet is compressed or shrunk substantially laterally with respect to the longitudinal axis of the plug element.

[0066] Alternatively, a sheet of web or paper material may be wound to form a substantially cylindrical, hollow tubular element. The thickness of the hollow tubular element may be adjusted by varying the number of windings or folds.

[0067] The plug element may comprise a single sheet of paper material that is assembled or otherwise processed to form a rod shape. Alternatively, the plug element may comprise two or more sheets that are assembled or otherwise processed together to form a rod shape. For example, two or more sheets of paper material may be placed on top of each other and assembled or otherwise processed at once to form a plug element. The two or more sheets of paper material may also be assembled or otherwise processed independently, parallel to each other, and then combined to form a plug element.

[0068] Alternatively, the plug element may comprise multiple sheets of paper material stacked on top of each other. The resulting stack may have a thickness of up to 10 millimeters. The stack may be cut into a rod-shaped element to form a plug element for use in the aerosol generating article according to the present invention.

[0069] Before being formed into rods or hollow tubular elements, sheets of web or paper material may be textured. Textured sheets of web or paper material can be advantageous in that they facilitate the assembly of the sheets into rods.

[0070] As used herein, the term “textured sheet” means a sheet that has been crimped, embossed, debossed, perforated, or otherwise deformed. A textured paper material sheet may include multiple spaced indentations, protrusions, perforations, or a combination thereof.

[0071] As used herein, the term “crimped sheet” is intended to be synonymous with the term “crimped sheet” and means a sheet having multiple substantially parallel ridges or undulations. Preferably, in a plug element formed by assembling sheets of crimped paper material, the crimped sheet has multiple ridges or undulations substantially parallel to the cylindrical axis of the plug element. This is advantageous as it facilitates the assembly of sheets of crimped paper material to form a rod. However, it is recognized that sheets of crimped paper material for use in plug elements of aerosol-generating articles described herein may, in an alternative or additional way, have multiple substantially parallel ridges or undulations arranged at acute or obtuse angles to the longitudinal axis of the plug element. Generally, providing multiple ridges or undulations increases the surface area of ​​the plug element formed from one of such crimped sheets, which may improve the filtration efficiency of the plug by facilitating contact between the aerosol or smoke flowing through the plug element and the additive coating.

[0072] In certain embodiments, a sheet of paper material for use in forming the plug elements described herein may have a substantially uniform texture substantially across its entire surface. For example, a crimped sheet of paper material for use in forming the plug elements described herein may include a plurality of substantially parallel ridges or undulations substantially evenly spaced across the width of the sheet.

[0073] The process of assembling or winding paper material sheets to form a plug element has the advantage that, by adjusting the number of folds or how closely the sheets are assembled, it is possible to ensure that the plug element exhibits the necessary resistance to mechanical deformation so that it can withstand being grasped by a consumer during smoking in an aerosol-generating article.

[0074] As briefly mentioned above, the paper material sheet may have a basis weight of at least 10 grams / square meter. Preferably, the paper material sheet may have a basis weight of at least 15 grams / square meter. More preferably, the paper material sheet may have a basis weight of at least 20 grams / square meter. Even more preferably, the paper material sheet may have a basis weight of at least 30 grams / square meter.

[0075] The paper material sheet may have a basis weight of 200 grams / square meter or less. Preferably, the paper material sheet may have a basis weight of 180 grams / square meter or less. More preferably, the paper material sheet may have a basis weight of 160 grams / square meter or less. Even more preferably, the paper material sheet may have a basis weight of 120 grams / square meter or less. In a particularly preferred embodiment, the paper material sheet may have a basis weight of 100 grams / square meter or less.

[0076] The basis weight of the paper material sheet may be selected based on a balance between the ability of the plug element to withstand compressive loads during use and the need to maintain a certain degree of flexibility in the paper material sheet so that it can be formed into a desired shape. Furthermore, the basis weight of the paper material sheet may be selected so that the plug element can withstand deformation during storage, transport, and use of the aerosol-generating article.

[0077] As briefly mentioned above, the paper material sheet may have a maximum thickness of 800 micrometers. Preferably, the paper material sheet has a thickness of 600 micrometers or less. More preferably, the paper material sheet has a thickness of 600 micrometers or less. Even more preferably, the paper material sheet has a thickness of 500 micrometers or less.

[0078] In a preferred embodiment, the paper material sheet has a thickness of 300 micrometers or less, preferably 200 micrometers or less, and more preferably 100 micrometers or less.

[0079] The paper material sheet may have a thickness of at least 10 micrometers. Preferably, the paper material sheet has a thickness of at least 15 micrometers. More preferably, the paper material sheet has a thickness of at least 20 micrometers. Even more preferably, the paper material sheet has a thickness of at least 30 micrometers.

[0080] In a preferred embodiment, the paper material sheet has a thickness of at least 40 micrometers, preferably at least 50 micrometers, and more preferably at least 60 micrometers.

[0081] The thickness of the sheet may be selected to ensure a certain degree of flexibility in the sheet, allowing for one or more of the following processes: crumpling, gathering, pleating, and folding.

[0082] The plug element may have a weight of approximately 100 milligrams or less, approximately 75 milligrams or less, or approximately 50 milligrams or less.

[0083] The plug element may have a weight of at least about 10 milligrams, at least about 15 milligrams, or at least about 20 milligrams.

[0084] The plug element may have a weight of approximately 10 milligrams to approximately 100 milligrams, approximately 10 milligrams to approximately 75 milligrams, or approximately 10 milligrams to approximately 50 milligrams.

[0085] The plug element may have a weight of approximately 15 milligrams to 100 milligrams, approximately 15 milligrams to 75 milligrams, or approximately 15 milligrams to 50 milligrams.

[0086] The plug element may have a weight of approximately 20 milligrams to 100 milligrams, approximately 20 milligrams to 75 milligrams, or approximately 20 milligrams to 50 milligrams.

[0087] The plug element may have an average weight per unit length of approximately 20 milligrams / millimeter or less, approximately 15 milligrams / millimeter or less, or approximately 10 milligrams / millimeter or less.

[0088] When used herein with reference to the present invention, the average weight per unit length of a plug element is equal to the weight of the plug element divided by the length of the plug element. For example, if a plug element has a weight of 25 milligrams and a length of 5 millimeters, the average weight per unit length of the plug element is 5 milligrams / millimeter.

[0089] The plug element may have an average weight per unit length of at least about 2 milligrams / millimeter, at least about 3 milligrams / millimeter, or at least about 4 milligrams / millimeter.

[0090] The plug element may have an average weight per unit length of approximately 2 milligrams / mm to approximately 20 milligrams / mm, approximately 2 milligrams / mm to approximately 15 milligrams / mm, or approximately 2 milligrams / mm to approximately 10 milligrams / mm.

[0091] The plug element may have an average weight per unit length of approximately 3 milligrams / mm to approximately 20 milligrams / mm, approximately 3 milligrams / mm to approximately 15 milligrams / mm, or approximately 3 milligrams / mm to approximately 10 milligrams / mm.

[0092] The plug element may have an average weight per unit length of approximately 4 milligrams / mm to approximately 20 milligrams / mm, approximately 4 milligrams / mm to approximately 15 milligrams / mm, or approximately 4 milligrams / mm to approximately 10 milligrams / mm.

[0093] In a plug element for use in an aerosol generating article according to the present invention, the additive coating may cover at least a portion of the outer surface of at least one side of the paper material sheet. Preferably, the additive coating covers at least a portion of the outer surfaces on both sides of the paper material sheet.

[0094] The additive coating may be applied to a portion of the outer surface of at least one side of the paper material sheet. Preferably, the additive coating is applied to a portion of the outer surface on both sides of the paper material sheet.

[0095] Alternatively, the additive coating may be applied to substantially all of the outer surfaces of at least one side of the sheet of paper material. Preferably, the additive coating may be applied to substantially all of the outer surfaces of at least one side of the sheet of paper material.

[0096] Therefore, in the aerosol-generating article according to the present invention, the additive coating can be applied to a paper material to form a defined layer on at least a portion of the outer surface of at least one side of the paper material. In some embodiments, the additive coating can be applied to a paper material to form a defined layer on at least a portion of the outer surface on both sides of the paper material. For example, this can be achieved by applying the additive coating to the paper material by a conventional printing process (e.g., gravure printing or flexographic printing) or by a well-known coating process (e.g., curtain coating, reverse gravure, semi-flexographic, rod coating, blade coating, comma coating, slot die coating).

[0097] Applying an additive coating to the outer surface of the paper material is advantageous because it maximizes contact between the additive coating and the mainstream smoke or aerosol passing through the downstream elements during use. This, in turn, maximizes the ability of the additive coating to reduce phenols and other undesirable compounds in the smoke or aerosol.

[0098] However, depending on the porosity of the paper material and due to the natural tendency of paper material to absorb liquids such as water, applying an additive coating to the paper material typically allows at least a portion of the additive coating to penetrate the paper material so that at least a portion of the volume of the paper material is immersed in the additive coating. This can occur particularly when the additive coating is provided in the form of an aqueous solution or dispersion.

[0099] Therefore, in the aerosol-generating article according to the present invention, the additive coating may, alternatively or additionally, be applied to the paper material to impregnate at least a portion of the volume of the paper material, rather than forming a defined layer on at least a portion of the outer surface of at least one side of the paper material. In such a case, the coating additive does not form a defined layer on the outer surface of the paper material. Instead, the coating additive is absorbed into the paper material and, upon drying, forms a deposit on the fibrous fraction of the paper material (i.e., on the individual cellulose fibers contained in the paper material). For example, at least partial impregnation of the paper material with the additive coating may be achieved by techniques such as "dip and squeeze," spray coating, comma coating, or by using a conventional or film-type press or blade applicator.

[0100] Providing such deposition of additive coatings on the cellulose fibers of paper materials, coupled with the inherent porosity of the paper material, advantageously ensures that mainstream smoke or aerosol passing through downstream elements comes into contact with the additive coating during use, and this interaction promotes the reduction of phenols and other undesirable compounds in the smoke or aerosol.

[0101] Accordingly, in certain embodiments of the aerosol generating article according to the present invention, the plug element may include a cellulosic filter material, and the additive coating forms a defined layer on at least a portion of the outer surface of at least one side of the paper material. In other embodiments of the aerosol generating article according to the present invention, the plug element may include a cellulosic filter material, and the additive coating is absorbed by the paper material, impregnating at least a portion of the volume of the paper material. In further embodiments of the aerosol generating article according to the present invention, the plug element may include a cellulosic filter material, and both the plug element and the additive coating are absorbed by the paper material, thus impregnating at least a portion of the volume of the paper material and forming a defined layer on at least a portion of the outer surface of at least one side of the paper material.

[0102] The plug element may contain at least 1 weight percent of additive coating. Preferably, the plug element contains at least 2 weight percent of additive coating, more preferably at least 3 weight percent of additive coating, more preferably at least 4 weight percent of additive coating, and more preferably at least 5 weight percent of additive coating, on a dry weight basis.

[0103] The plug element may include, on a dry weight basis, up to 15 weight percent of additive coating, preferably up to 12 weight percent of additive coating, and more preferably up to 10 weight percent of additive coating.

[0104] The plug element may include an additive coating of 1% to 15% by weight, preferably 2% to 15% by weight, more preferably 3% to 15% by weight, more preferably 4% to 15% by weight, and particularly preferably 5% to 15% by weight.

[0105] The plug element may include an additive coating of 1% to 12% by weight, preferably 2% to 12% by weight, more preferably 3% to 12% by weight, more preferably 4% to 12% by weight, and particularly preferably 5% to 12% by weight.

[0106] The plug element may include an additive coating of 1% to 10% by weight, preferably 2% to 10% by weight, more preferably 3% to 10% by weight, more preferably 4% to 10% by weight, and particularly preferably 5% to 10% by weight.

[0107] The additive coating includes at least one additive for reducing phenol. That is, the additive coating includes at least one additive that can capture or otherwise convert at least a portion of the phenol and phenol derivatives produced when the aerosol generating substrate is heated or burned. Preferably, the additive coating includes at least one additive for reducing other undesirable compounds from mainstream aerosols, such as carbon monoxide and formaldehyde.

[0108] The additive coating is preferably biodegradable so that the cellulose-based filter material, including the combination of the additive coating and the paper material, is biodegradable.

[0109] The additive coating may contain at least 5% by weight of at least one exogenous polysaccharide on a dry weight basis. Preferably, the additive coating contains at least 6% by weight of at least one exogenous polysaccharide on a dry weight basis, more preferably at least 8% by weight of exogenous lignin, more preferably at least 10% by weight of at least one exogenous polysaccharide, more preferably at least 12% by weight of at least one exogenous polysaccharide, and more preferably at least 15% by weight of at least one exogenous polysaccharide.

[0110] The additive coating preferably contains, on a dry weight basis, at least 50% by weight of at least one exogenous polysaccharide, more preferably at least 45% by weight of at least one exogenous polysaccharide, more preferably at least 40% by weight of at least one exogenous polysaccharide, more preferably at least 35% by weight of at least one exogenous polysaccharide, and even more preferably at least 30% by weight of at least one exogenous polysaccharide.

[0111] For example, the additive coating may consist of, on a dry weight basis, at least one exogenous polysaccharide in an amount of 5% to 50% by weight, or at least one exogenous polysaccharide in an amount of 6% to 50% by weight, or at least one exogenous polysaccharide in an amount of 8% to 50% by weight, or at least one exogenous polysaccharide in an amount of 10% to 50% by weight, or at least one exogenous polysaccharide in an amount of 12% to 50% by weight, or at least one exogenous polysaccharide in an amount of 15% to 50% by weight, or 5% by weight At least one exogenous polysaccharide in 10% to 45% by weight, or at least one exogenous polysaccharide in 6% to 45% by weight, or at least one exogenous polysaccharide in 8% to 45% by weight, or at least one exogenous polysaccharide in 10% to 45% by weight, or at least one exogenous polysaccharide in 12% to 45% by weight, or at least one exogenous polysaccharide in 15% to 45% by weight, or at least one in 5% to 40% by weight Exogenous polysaccharides, or at least one exogenous polysaccharide in 6% to 40% by weight, or at least one exogenous polysaccharide in 8% to 40% by weight, or at least one exogenous polysaccharide in 10% to 40% by weight, or at least one exogenous polysaccharide in 12% to 40% by weight, or at least one exogenous polysaccharide in 15% to 40% by weight, or at least one exogenous polysaccharide in 5% to 35% by weight, or 6% to 35 At least one exogenous polysaccharide in weight percent, or at least one exogenous polysaccharide in 8 to 35 weight percent, or at least one exogenous polysaccharide in 10 to 35 weight percent, or at least one exogenous polysaccharide in 12 to 35 weight percent, or at least one exogenous polysaccharide in 15 to 35 weight percent, or at least one exogenous polysaccharide in 5 to 30 weight percent, or at least one exogenous polysaccharide in 6 to 30 weight percent,Alternatively, it may contain at least one exogenous polysaccharide in an amount of 8% to 30% by weight, or at least one exogenous polysaccharide in an amount of 10% to 30% by weight, or at least one exogenous polysaccharide in an amount of 12% to 30% by weight, or at least one exogenous polysaccharide in an amount of 15% to 30% by weight.

[0112] At least one exogenous polysaccharide provides numerous active functional groups, such as hydroxymethyl groups, that can be captured from smoke or aerosols, and these are certain gaseous compounds that may play a role in causing the dry, bitter sensation often associated with conventional paper filters. These compounds may include, but are not limited to, several weakly acidic compounds such as aldehydes, as well as certain esters, ketones, alcohols, and pyrroles.

[0113] Therefore, including at least one exogenous polysaccharide in the above-mentioned amounts reduces the content of such compounds in the mainstream smoke or aerosol as it passes from the aerosol-generating substrate through the downstream plug element.

[0114] As briefly described above, in the aerosol generating article according to the present invention, the overall dry weight content of at least one exogenous polysaccharide in the plug element is at least 5 weight percent, preferably at least 6 weight percent, more preferably at least 7 weight percent, and even more preferably at least 8 weight percent.

[0115] The total content of at least one exogenous polysaccharide in the plug element on a dry weight basis may be up to 20 weight percent. Preferably, the total content of at least one exogenous polysaccharide in the plug element on a dry weight basis is up to 18 weight percent, more preferably up to 15 weight percent, and even more preferably up to 12 weight percent. In some embodiments, the total content of at least one exogenous polysaccharide in the plug element on a dry weight basis is up to 10 weight percent.

[0116] For example, the total content of at least one exogenous polysaccharide in the plug element on a dry weight basis is 5% to 20% by weight, preferably 6% to 20% by weight, more preferably 7% to 20% by weight, and even more preferably 8% to 20% by weight.

[0117] For example, the total content of at least one exogenous polysaccharide in the plug element on a dry weight basis is 5% to 18% by weight, preferably 6% to 18% by weight, more preferably 7% to 18% by weight, and even more preferably 8% to 18% by weight.

[0118] For example, the total content of at least one exogenous polysaccharide in the plug element on a dry weight basis is 5% to 15% by weight, preferably 6% to 15% by weight, more preferably 7% to 15% by weight, and even more preferably 8% to 15% by weight.

[0119] For example, the total content of at least one exogenous polysaccharide in the plug element on a dry weight basis is 5% to 12% by weight, preferably 6% to 12% by weight, more preferably 7% to 12% by weight, and even more preferably 8% to 12% by weight.

[0120] For example, the total content of at least one exogenous polysaccharide in the plug element on a dry weight basis is 5% to 10% by weight, preferably 6% to 10% by weight, more preferably 7% to 10% by weight, and even more preferably 8% to 10% by weight.

[0121] At least one exogenous polysaccharide is preferably selected from the group consisting of starch, modified starch, alkenyl succinate starch, pullulan, alginates, and combinations thereof. Suitable types of starch include, but are not limited to, potato starch, rice starch, cassava starch, and corn starch.

[0122] The term "starch" is used herein with reference to the present invention to refer to a high-molecular-weight carbohydrate consisting of multiple glucose units linked by α-(1→4)-D glycosidic bonds. In nature, starch is produced in most green plants for the purpose of energy storage.

[0123] From a chemical standpoint, starch is primarily composed of two types of molecules: amylose and amylopectin. Amylose is characterized by a linear helical structure, while amylopectin is highly branched. Different types of starch typically contain different proportions of amylose and amylopectin. For example, potato starch and corn starch contain amylopectin and amylose in a ratio of approximately 3:1, while waxy corn starch is formed almost entirely from amylose.

[0124] In some embodiments, at least one exogenous polysaccharide is a modified starch such as oxidized waxy potato starch, or lightly boiled starch, or acetylated starch, or oxidized and lightly acetylated starch.

[0125] In preferred embodiments, at least one exogenous polysaccharide comprises acetylated starch or oxidized and slightly acetylated starch.

[0126] Acetylated starch is a form of modified starch that has been modified to increase the number of acetyl groups. As a result of the increased number of acetyl groups, the use of acetylated starch may improve the starch's ability to reduce phenol from mainstream aerosols.

[0127] While we do not wish to be bound by theory, it is understood that the introduction of acetyl groups also affects the wettability of paper materials. In fact, the esterification reaction that occurs between acetyl groups and at least some hydroxyl groups in cellulose molecules changes the properties of at least some cellulose fibers from hydrophilic to hydrophobic. Therefore, paper materials coated with an additive coating containing acetylated starch may have a reduced tendency to absorb moisture from smoke or aerosols flowing through the plug element. This is desirable in that it counteracts an effect often called "dry smoke," observed in some conventional cellulose acetate filters, where the moisture content of the smoke or aerosol delivered to the consumer is significantly reduced, and therefore may be perceived as undesirable dryness under certain conditions. Furthermore, increasing the contact angle of the paper material, for example, by increasing the contact angle of the paper material to more than 90 degrees, preferably more than 105 degrees, may advantageously reduce the paper material's ability to remove nicotine from smoke or aerosols.

[0128] Furthermore, including starch or modified starch in the additive coating has the additional benefit that the starch helps to bind the fibers of the paper material, and this effect is particularly important for airlaid substrates.

[0129] The additive coating preferably includes at least one additive for reducing phenol.

[0130] At least one additive for reducing phenol may be, for example, an ester of a polycarboxylic acid such as an ester of oxalic acid, malonic acid, succinic acid, citric acid, or isocitric acid. In a preferred embodiment, at least one additive for reducing phenol is an ester of citric acid, such as triethyl citrate (TEC).

[0131] At least one additive for reducing phenol may be a polyether, preferably a polyol. As used herein, the term "polyol" refers to a polyether having multiple hydroxyl groups. Examples of polyether polyols include polyethylene oxide, polyethylene glycol (PEG), polypropylene glycol (PPG), polytetrahydrofuran, and polytetramethylene ether glycol (PTMEG).

[0132] In a preferred embodiment, at least one additive for reducing phenol is polyethylene glycol (PEG).

[0133] At least one additive for reducing phenol may include a derivative of PEG, such as an ester of a PEG oligomer (e.g., diethylene glycol diacetate, trimethylethylene glycol diacetate).

[0134] At least one additive for reducing phenol may include a copolymer of PEG and PPG.

[0135] At least one additive for reducing phenol is preferably selected from the group consisting of triethyl citrate, polyethylene glycol, and combinations thereof.

[0136] At least one additive for reducing phenol may be triacetin.

[0137] At least one additive for reducing phenol may include acetylated or short-chain or medium-chain fatty acid plasticizers. For example, at least one additive for reducing phenol may include acetylated monoglycerides, isosorbide diesters (such as isosorbide diacetate or isosorbide butyrate).

[0138] At least one additive for reducing phenol may include at least one ethoxylated castor oil. Ethoxylated castor oil is obtained from the reaction of castor oil with ethylene oxide (ethoxylation process). Castor oil is a vegetable oil pressed from castor beans. At room temperature, it is a colorless or pale yellow liquid with a boiling point of about 313°C and a density of about 0.96 grams / cubic centimeter. Castor oil consists mainly of a mixture of triglycerides containing (85-85%) ricinoleic acid, in combination with oleic acid and linoleic acid as other significant components.

[0139] The chain length and average molecular weight of ethoxylated castor oil depend on the amount of ethylene oxide used during synthesis. Castor oil may be hydrogenated before or after the ethoxylation process. Hydrogenation of castor oil removes at least some of the double bonds present in ricinol or other fatty acid moieties. This has been found to favorably enhance the thermal and photostability of ethoxylated castor oil.

[0140] The term "molecular weight" is used to mean the sum of the atomic weights of each individual atom in a given molecule. However, polymer molecules generally exhibit a certain degree of variability with respect to molecular weight and polymer chain length, which can depend, for example, on the conditions under which polymerization occurs. Therefore, because there is a distribution of molecular weight, the term "average molecular weight" is typically used when describing polymer molecules to explain the degree of variability.

[0141] "Number-average molecular weight" is defined as the total weight of a polymer divided by the total number of molecules. "Weight-average molecular weight" depends not only on the number of molecules present but also on the weight of each molecule. Since larger molecules in a sample weigh more than smaller molecules, the weight-average molecular weight is inevitably skewed towards a higher value and is always greater than the number-average molecular weight. An increase in the number-average molecular weight generally accompanies an overall increase in the density of the polymer. Therefore, depending on their number-average molecular weight, some ethoxylated castor oils may be described as liquid at room temperature, while others may be described as semi-liquid, paste, or waxy solid. This may affect the ease with which additive coatings containing ethoxylated castor oil are applied to a substrate.

[0142] In the additive coating of the aerosol generating article according to the present invention, it is preferable that at least one ethoxylated castor oil has a number average molecular weight of at least 1080 daltons, more preferably at least 1200 daltons, and even more preferably at least 1600 daltons.

[0143] In addition, or by another method, in the additive coating of the aerosol generating article according to the present invention, it is preferable that at least one ethoxylated castor oil has a number average molecular weight of 3000 daltons or less.

[0144] In certain embodiments, the additive coating comprises at least one ethoxylated castor oil having a number average molecular weight of 1080 to 3000 daltons, preferably 1200 to 3000 daltons, and more preferably 1600 to 3000 daltons.

[0145] The inventors have found that ethoxylated castor oil having a number-average molecular weight within the above-mentioned range can be reliably and consistently coated onto a cellulosic filter material intended for use as a substrate for manufacturing components for use in the aerosol generating article according to the present invention.

[0146] In the additive coating of an aerosol-generating article according to the present invention, it is preferable that at least one ethoxylated castor oil is obtained by reacting 1 stoichiometric equivalent of castor oil with 1 to 50 stoichiometric equivalents of ethylene oxide. Different ethoxylated castor oil compounds are labeled PEG-x, where x indicates the number of ethylene oxide moieties per portion of castor oil involved in the reaction.

[0147] In the additive coating of an aerosol generating article according to the present invention, it is more preferable that at least one ethoxylated castor oil is obtained by reacting 1 stoichiometric equivalent of castor oil with 5 to 45 stoichiometric equivalents of ethylene oxide.

[0148] In the additive coating of an aerosol-generating article according to the present invention, it is even more preferable that at least one ethoxylated castor oil is obtained by reacting 1 stoichiometric equivalent of castor oil with 10 to 40 stoichiometric equivalents of ethylene oxide.

[0149] While we do not wish to be bound by theory, it is hypothesized that a higher stoichiometric ratio of ethylene oxide to castor oil is associated with a reduced tendency for ethoxylated castor oil to migrate when applied to a substrate such as a cellulosic filter material of interest in the context of this disclosure.

[0150] Particularly preferred ethoxylated castor oil compounds for inclusion in the additive coating of the aerosol-generating article according to the present invention include PEG-10, PEG-25, and PEG-40 (ethoxylated castor oil according to INCI nomenclature).

[0151] At least one additive for reducing phenol may include at least one polysorbate.

[0152] Polysorbates are oily liquids derived from ethoxylated sorbitan (a derivative of sorbitol) esterified with fatty acids. They are commonly used as emulsifiers in pharmaceuticals, food preparations, and cosmetics, facilitating the solubilization of essential oils in aqueous compositions.

[0153] Examples of polysorbates include polysorbate 20 (polyoxyethylene(20) sorbitan monolaurate), polysorbate 40 (polyoxyethylene(20) sorbitan monopalmitate), polysorbate 60 (polyoxyethylene(20) sorbitan monostearate), and polysorbate 80 (polyoxyethylene(20) sorbitan monooleate). The number following "polysorbate" helps to identify the main fatty acids associated with the molecule.

[0154] At least one additive for reducing phenol may include a polyadipic acid ester (CAS number: 24938-37-2).

[0155] Polyedipate esters, or poly(ethylene adipic acid), or PEA are aliphatic polyesters. They can be obtained by polycondensation reactions between ethylene glycol and adipic acid. PEAs are available in high or low molecular weight forms, such as 10,000 daltons or 1,000 daltons. Their use in the context of this disclosure is particularly advantageous because they are biodegradable through various mechanisms and are also relatively inexpensive.

[0156] The additive coating preferably contains at least 5% by weight of at least one additive for reducing phenol, more preferably at least 6% by weight of at least one additive for reducing phenol, more preferably at least 8% by weight of at least one additive for reducing phenol, and more preferably at least 10% by weight of an additive for reducing phenol.

[0157] The additive coating preferably contains up to 20% by weight of at least one additive for reducing phenol, more preferably up to 18% by weight of at least one additive for reducing phenol, more preferably up to 15% of at least one additive for reducing phenol, and more preferably up to 12% of at least one additive for reducing phenol, on a dry weight basis.

[0158] For example, the additive coating may contain, on a dry weight basis, at least one additive for reducing phenol in a quantity of 5% to 20% by weight, or at least one additive for reducing phenol in a quantity of 6% to 20% by weight, or at least one additive for reducing phenol in a quantity of 8% to 20% by weight, or at least one additive for reducing phenol in a quantity of 10% to 20% by weight, or at least one additive for reducing phenol in a quantity of 5% to 18% by weight, or at least one additive for reducing phenol in a quantity of 6% to 18% by weight, or at least one additive for reducing phenol in a quantity of 8% to 18% by weight, or at least one additive for reducing phenol in a quantity of 10% to 18% by weight. It may also contain 5 to 15 weight percent of at least one additive for reducing phenol, or 6 to 15 weight percent of at least one additive for reducing phenol, or 8 to 15 weight percent of at least one additive for reducing phenol, or 10 to 15 weight percent of at least one additive for reducing phenol, or 5 to 12 weight percent of at least one additive for reducing phenol, or 6 to 12 weight percent of at least one additive for reducing phenol, or 8 to 12 weight percent of at least one additive for reducing phenol, or 10 to 12 weight percent of at least one additive for reducing phenol.

[0159] By applying one of these additives to the paper material of the downstream element, the downstream element has the ability to capture or otherwise convert at least a portion of the phenol produced by the aerosol-generating article. Therefore, including at least one additive for phenol reduction, in addition to at least one exogenous polysaccharide, in the cellulosic filter material helps to reduce the level of phenol in the mainstream aerosol as it passes from the aerosol-generating substrate to the downstream plug element, while minimizing undesirable effects on the consumer's taste experience.

[0160] In the aerosol-generating article according to the present invention, the total content of at least one additive for reducing phenol in the plug element, on a dry weight basis, is at least 0.5 weight percent, preferably at least 1 weight percent, more preferably at least 1.5 weight percent, and even more preferably at least 2 weight percent.

[0161] In some embodiments, the overall content of at least one additive for reducing phenol in the plug element on a dry weight basis is at least 3% by weight, preferably at least 4% by weight, and more preferably at least 5% by weight.

[0162] The total content of at least one additive for reducing phenol in the plug element on a dry weight basis may be up to 15 weight percent. Preferably, the total content of at least one additive for reducing phenol in the plug element on a dry weight basis is up to 12 weight percent, and more preferably up to 10 weight percent.

[0163] For example, the overall content of at least one additive for reducing phenol in the plug element on a dry weight basis is 0.5 to 15 weight percent, preferably 1 to 15 weight percent, more preferably 1.5 to 15 weight percent, and even more preferably 2 to 15 weight percent. In some embodiments, the overall content of at least one additive for reducing phenol in the plug element on a dry weight basis is 3 to 15 weight percent, preferably 4 to 15 weight percent, and more preferably 5 to 15 weight percent.

[0164] For example, the overall content of at least one additive for reducing phenol in the plug element on a dry weight basis is 0.5 to 12 weight percent, preferably 1 to 12 weight percent, more preferably 1.5 to 12 weight percent, and even more preferably 2 to 12 weight percent. In some embodiments, the overall content of at least one additive for reducing phenol in the plug element on a dry weight basis is 3 to 12 weight percent, preferably 4 to 12 weight percent, and more preferably 5 to 12 weight percent.

[0165] For example, the overall content of at least one additive for reducing phenol in the plug element on a dry weight basis is 0.5 to 10 weight percent, preferably 1 to 10 weight percent, more preferably 1.5 to 10 weight percent, and even more preferably 2 to 10 weight percent. In some embodiments, the overall content of at least one additive for reducing phenol in the plug element on a dry weight basis is 3 to 10 weight percent, preferably 4 to 10 weight percent, and more preferably 5 to 10 weight percent.

[0166] The combined amount of exogenous polysaccharides and additives for reducing phenol in the additive coating is at least 10 weight percent, more preferably at least 12 weight percent, more preferably at least 14 weight percent, more preferably at least 16 weight percent, and more preferably at least 18 weight percent, on a dry weight basis.

[0167] The combined amount of exogenous polysaccharides and phenols in the additive coating is preferably up to 30 weight percent, more preferably up to 28 weight percent, more preferably up to 26 weight percent, more preferably up to 24 weight percent, and more preferably up to 22 weight percent, on a dry weight basis.

[0168] For example, the combined amounts of additives for reducing exogenous polysaccharides and phenols in the additive coating may be 10% to 30% by weight, or 12% to 28% by weight, or 14% to 26% by weight, or 16% to 24% by weight, or 18% to 22% by weight, on a dry weight basis.

[0169] The weight ratio of exogenous polysaccharides to additives for reducing phenol in the additive coating may be 0.25 to 4, for example, 0.5 to 3, or 0.75 to 3, or 1 to 3, or 0.5 to 2.5, or 0.75 to 2.5, or 1 to 2.5, or 0.5 to 2, or 0.75 to 2, or 1 to 2.

[0170] In embodiments where the additive for reducing phenol includes polyethylene glycol, the additive coating may contain at least 1 weight percent of polyethylene glycol based on the dry weight of the paper material. Preferably, the additive coating contains at least 2 weight percent of polyethylene glycol based on the dry weight of the paper material. More preferably, the additive coating contains at least 3 weight percent of polyethylene glycol based on the dry weight of the paper material. Even more preferably, the additive coating contains at least 5 weight percent of polyethylene glycol based on the dry weight of the paper material.

[0171] The additive coating may contain, for example, up to 12 weight percent of polyethylene glycol based on the dry weight of the paper material, on a dry weight basis. Preferably, the additive coating contains 10 weight percent or less of polyethylene glycol based on the dry weight of the paper material, on a dry weight basis. More preferably, the additive coating contains 9 weight percent or less of polyethylene glycol based on the dry weight of the paper material, on a dry weight basis. Even more preferably, the additive coating contains 8 weight percent or less of polyethylene glycol based on the dry weight of the paper material, on a dry weight basis.

[0172] In some embodiments, the additive coating contains 1% to 12% by weight polyethylene glycol on a dry weight basis, based on the dry weight of the paper material. Preferably, the additive coating contains 2% to 12% by weight polyethylene glycol on a dry weight basis, based on the dry weight of the paper material. More preferably, the additive coating contains 3% to 12% by weight polyethylene glycol on a dry weight basis, based on the dry weight of the paper material. Even more preferably, the additive coating contains 5% to 12% by weight polyethylene glycol on a dry weight basis, based on the dry weight of the paper material.

[0173] In other embodiments, the additive coating contains 1% to 10% by weight polyethylene glycol on a dry weight basis, based on the dry weight of the paper material. Preferably, the additive coating contains 2% to 10% by weight polyethylene glycol on a dry weight basis, based on the dry weight of the paper material. More preferably, the additive coating contains 3% to 10% by weight polyethylene glycol on a dry weight basis, based on the dry weight of the paper material. Even more preferably, the additive coating contains 5% to 10% by weight polyethylene glycol on a dry weight basis, based on the dry weight of the paper material.

[0174] In further embodiments, the additive coating contains 1% to 9% by weight polyethylene glycol on a dry weight basis, based on the dry weight of the paper material. Preferably, the additive coating contains 2% to 9% by weight polyethylene glycol on a dry weight basis, based on the dry weight of the paper material. More preferably, the additive coating contains 3% to 9% by weight polyethylene glycol on a dry weight basis, based on the dry weight of the paper material. Even more preferably, the additive coating contains 5% to 9% by weight polyethylene glycol on a dry weight basis, based on the dry weight of the paper material.

[0175] In further embodiments, the additive coating contains 1% to 8% by weight polyethylene glycol on a dry weight basis, based on the dry weight of the paper material. Preferably, the additive coating contains 2% to 8% by weight polyethylene glycol on a dry weight basis, based on the dry weight of the paper material. More preferably, the additive coating contains 3% to 8% by weight polyethylene glycol on a dry weight basis, based on the dry weight of the paper material. Even more preferably, the additive coating contains 5% to 8% by weight polyethylene glycol on a dry weight basis, based on the dry weight of the paper material.

[0176] In a preferred embodiment, the additive coating comprises polyethylene glycol in an amount consistent with the above description, combined with acetylated starch oxide.

[0177] For example, the additive coating may contain 5 weight percent of acetylated starch on a dry weight basis, combined with polyethylene glycol in an amount consistent with the above description, based on the dry weight of the paper material. Preferably, the additive coating contains at least 6 weight percent of acetylated starch on a dry weight basis, combined with polyethylene glycol in an amount consistent with the above description, based on the dry weight of the paper material. More preferably, the additive coating contains at least 8 weight percent of acetylated starch on a dry weight basis, combined with polyethylene glycol in an amount consistent with the above description, based on the dry weight of the paper material.

[0178] In embodiments where the additive for reducing phenol contains ethoxylated castor oil, the additive coating may contain at least 1 weight percent of ethoxylated castor oil on a dry weight basis, based on the dry weight of the paper material. Preferably, the additive coating contains at least 2 weight percent of ethoxylated castor oil on a dry weight basis, based on the dry weight of the paper material. More preferably, the additive coating contains at least 3 weight percent of ethoxylated castor oil on a dry weight basis, based on the dry weight of the paper material. Even more preferably, the additive coating contains at least 5 weight percent of ethoxylated castor oil on a dry weight basis, based on the dry weight of the paper material.

[0179] The additive coating may contain, for example, up to 12 weight percent of ethoxylated castor oil based on the dry weight of the paper material. Preferably, the additive coating contains 10 weight percent or less of ethoxylated castor oil based on the dry weight of the paper material. More preferably, the additive coating contains 9 weight percent or less of ethoxylated castor oil based on the dry weight of the paper material. Even more preferably, the additive coating contains 8 weight percent or less of ethoxylated castor oil based on the dry weight of the paper material.

[0180] In some embodiments, the additive coating contains 1% to 12% by weight of ethoxylated castor oil on a dry weight basis, based on the dry weight of the paper material. Preferably, the additive coating contains 2% to 12% by weight of ethoxylated castor oil on a dry weight basis, based on the dry weight of the paper material. More preferably, the additive coating contains 3% to 12% by weight of ethoxylated castor oil on a dry weight basis, based on the dry weight of the paper material. Even more preferably, the additive coating contains 5% to 12% by weight of ethoxylated castor oil on a dry weight basis, based on the dry weight of the paper material.

[0181] In other embodiments, the additive coating contains 1% to 10% by weight of ethoxylated castor oil on a dry weight basis, based on the dry weight of the paper material. Preferably, the additive coating contains 2% to 10% by weight of ethoxylated castor oil on a dry weight basis, based on the dry weight of the paper material. More preferably, the additive coating contains 3% to 10% by weight of ethoxylated castor oil on a dry weight basis, based on the dry weight of the paper material. Even more preferably, the additive coating contains 5% to 10% by weight of ethoxylated castor oil on a dry weight basis, based on the dry weight of the paper material.

[0182] In further embodiments, the additive coating contains 1% to 9% by weight of ethoxylated castor oil on a dry weight basis, based on the dry weight of the paper material. Preferably, the additive coating contains 2% to 9% by weight of ethoxylated castor oil on a dry weight basis, based on the dry weight of the paper material. More preferably, the additive coating contains 3% to 9% by weight of ethoxylated castor oil on a dry weight basis, based on the dry weight of the paper material. Even more preferably, the additive coating contains 5% to 9% by weight of ethoxylated castor oil on a dry weight basis, based on the dry weight of the paper material.

[0183] In further embodiments, the additive coating contains 1% to 8% by weight of ethoxylated castor oil on a dry weight basis, based on the dry weight of the paper material. Preferably, the additive coating contains 2% to 8% by weight of ethoxylated castor oil on a dry weight basis, based on the dry weight of the paper material. More preferably, the additive coating contains 3% to 8% by weight of ethoxylated castor oil on a dry weight basis, based on the dry weight of the paper material. Even more preferably, the additive coating contains 5% to 8% by weight of ethoxylated castor oil on a dry weight basis, based on the dry weight of the paper material.

[0184] In a preferred embodiment, the additive coating comprises an amount of ethoxylated castor oil in accordance with the above description, combined with acetylated oxidized starch.

[0185] For example, the additive coating may contain 5% by weight of acetylated oxidized starch on a dry weight basis, combined with ethoxylated castor oil in an amount consistent with the above description, based on the dry weight of the paper material. Preferably, the additive coating contains at least 6% by weight of acetylated oxidized starch on a dry weight basis, combined with ethoxylated castor oil in an amount consistent with the above description, based on the dry weight of the paper material. More preferably, the additive coating contains at least 8% by weight of acetylated oxidized starch on a dry weight basis, combined with ethoxylated castor oil in an amount consistent with the above description, based on the dry weight of the paper material.

[0186] In embodiments where the additive for reducing phenol includes polysorbate, the additive coating may contain at least 1 weight percent of polysorbate based on the dry weight of the paper material, on a dry weight basis. Preferably, the additive coating contains at least 2 weight percent of polysorbate based on the dry weight of the paper material, on a dry weight basis. More preferably, the additive coating contains at least 3 weight percent of polysorbate based on the dry weight of the paper material, on a dry weight basis. Even more preferably, the additive coating contains at least 5 weight percent of polysorbate based on the dry weight of the paper material, on a dry weight basis.

[0187] The additive coating may, for example, contain up to 12 weight percent of polysorbate based on the dry weight of the paper material, on a dry weight basis. Preferably, the additive coating contains 10 weight percent or less of polysorbate based on the dry weight of the paper material, on a dry weight basis. More preferably, the additive coating contains 9 weight percent or less of polysorbate based on the dry weight of the paper material, on a dry weight basis. Even more preferably, the additive coating contains 8 weight percent or less of polysorbate based on the dry weight of the paper material, on a dry weight basis.

[0188] In some embodiments, the additive coating contains 1% to 12% by weight of polysorbate on a dry weight basis, based on the dry weight of the paper material. Preferably, the additive coating contains 2% to 12% by weight of polysorbate on a dry weight basis, based on the dry weight of the paper material. More preferably, the additive coating contains 3% to 12% by weight of polysorbate on a dry weight basis, based on the dry weight of the paper material. Even more preferably, the additive coating contains 5% to 12% by weight of polysorbate on a dry weight basis, based on the dry weight of the paper material.

[0189] In other embodiments, the additive coating contains 1% to 10% by weight of polysorbate on a dry weight basis, based on the dry weight of the paper material. Preferably, the additive coating contains 2% to 10% by weight of polysorbate on a dry weight basis, based on the dry weight of the paper material. More preferably, the additive coating contains 3% to 10% by weight of polysorbate on a dry weight basis, based on the dry weight of the paper material. Even more preferably, the additive coating contains 5% to 10% by weight of polysorbate on a dry weight basis, based on the dry weight of the paper material.

[0190] In further embodiments, the additive coating contains 1% to 9% by weight of polysorbate on a dry weight basis, based on the dry weight of the paper material. Preferably, the additive coating contains 2% to 9% by weight of polysorbate on a dry weight basis, based on the dry weight of the paper material. More preferably, the additive coating contains 3% to 9% by weight of polysorbate on a dry weight basis, based on the dry weight of the paper material. Even more preferably, the additive coating contains 5% to 9% by weight of polysorbate on a dry weight basis, based on the dry weight of the paper material.

[0191] In further embodiments, the additive coating contains 1% to 8% by weight of polysorbate on a dry weight basis, based on the dry weight of the paper material. Preferably, the additive coating contains 2% to 8% by weight of polysorbate on a dry weight basis, based on the dry weight of the paper material. More preferably, the additive coating contains 3% to 8% by weight of polysorbate on a dry weight basis, based on the dry weight of the paper material. Even more preferably, the additive coating contains 5% to 8% by weight of polysorbate on a dry weight basis, based on the dry weight of the paper material.

[0192] In a preferred embodiment, the additive coating comprises an amount of polysorbate in accordance with the above description, combined with acetylated starch oxide.

[0193] For example, the additive coating may contain 5 weight percent of acetylated starch on a dry weight basis, combined with polysorbate in an amount consistent with the above description, based on the dry weight of the paper material. Preferably, the additive coating contains at least 6 weight percent of acetylated starch on a dry weight basis, combined with polysorbate in an amount consistent with the above description, based on the dry weight of the paper material. More preferably, the additive coating contains at least 8 weight percent of acetylated starch on a dry weight basis, combined with polysorbate in an amount consistent with the above description, based on the dry weight of the paper material.

[0194] In embodiments where the additive for reducing phenol includes polyadipic acid ester, the additive coating may contain at least 1 weight percent of polyadipic acid ester based on the dry weight of the paper material. Preferably, the additive coating contains at least 2 weight percent of polyadipic acid ester based on the dry weight of the paper material. More preferably, the additive coating contains at least 3 weight percent of polyadipic acid ester based on the dry weight of the paper material. Even more preferably, the additive coating contains at least 5 weight percent of polyadipic acid ester based on the dry weight of the paper material.

[0195] The additive coating may contain, for example, up to 12 weight percent of polyadipate esters based on the dry weight of the paper material. Preferably, the additive coating contains 10 weight percent or less of polyadipate esters based on the dry weight of the paper material. More preferably, the additive coating contains 9 weight percent or less of polyadipate esters based on the dry weight of the paper material. Even more preferably, the additive coating contains 8 weight percent or less of polyadipate esters based on the dry weight of the paper material.

[0196] In some embodiments, the additive coating contains 1% to 12% by weight of polyadipate ester on a dry weight basis, based on the dry weight of the paper material. Preferably, the additive coating contains 2% to 12% by weight of polyadipate ester on a dry weight basis, based on the dry weight of the paper material. More preferably, the additive coating contains 3% to 12% by weight of polyadipate ester on a dry weight basis, based on the dry weight of the paper material. Even more preferably, the additive coating contains 5% to 12% by weight of polyadipate ester on a dry weight basis, based on the dry weight of the paper material.

[0197] In other embodiments, the additive coating contains 1% to 10% by weight of polyadipate ester on a dry weight basis, based on the dry weight of the paper material. Preferably, the additive coating contains 2% to 10% by weight of polyadipate ester on a dry weight basis, based on the dry weight of the paper material. More preferably, the additive coating contains 3% to 10% by weight of polyadipate ester on a dry weight basis, based on the dry weight of the paper material. Even more preferably, the additive coating contains 5% to 10% by weight of polyadipate ester on a dry weight basis, based on the dry weight of the paper material.

[0198] In further embodiments, the additive coating contains 1% to 9% by weight of polyadipate esters on a dry weight basis, based on the dry weight of the paper material. Preferably, the additive coating contains 2% to 9% by weight of polyadipate esters on a dry weight basis, based on the dry weight of the paper material. More preferably, the additive coating contains 3% to 9% by weight of polyadipate esters on a dry weight basis, based on the dry weight of the paper material. Even more preferably, the additive coating contains 5% to 9% by weight of polyadipate esters on a dry weight basis, based on the dry weight of the paper material.

[0199] In further embodiments, the additive coating contains 1% to 8% by weight of polyadipate esters on a dry weight basis, based on the dry weight of the paper material. Preferably, the additive coating contains 2% to 8% by weight of polyadipate esters on a dry weight basis, based on the dry weight of the paper material. More preferably, the additive coating contains 3% to 8% by weight of polyadipate esters on a dry weight basis, based on the dry weight of the paper material. Even more preferably, the additive coating contains 5% to 8% by weight of polyadipate esters on a dry weight basis, based on the dry weight of the paper material.

[0200] In a preferred embodiment, the additive coating comprises an amount of polyadipic acid ester in accordance with the above description, combined with acetylated oxidized starch.

[0201] For example, the additive coating may contain 5 weight percent of acetylated oxidized starch on a dry weight basis, combined with the polyadipic acid ester in an amount consistent with the above description, based on the dry weight of the paper material. Preferably, the additive coating contains at least 6 weight percent of acetylated oxidized starch on a dry weight basis, combined with the polyadipic acid ester in an amount consistent with the above description, based on the dry weight of the paper material. More preferably, the additive coating contains at least 8 weight percent of acetylated oxidized starch on a dry weight basis, combined with the polyadipic acid ester in an amount consistent with the above description, based on the dry weight of the paper material.

[0202] In addition to additives for reducing exogenous polysaccharides and phenols, the additive coating may contain at least one surfactant.

[0203] The term "surfactant" is used to refer to a compound adapted to reduce the surface tension or interfacial tension between two liquids, such as a liquid and a gas, or a liquid and a solid. From a chemical standpoint, surfactant molecules contain both hydrophilic functional groups that exhibit an affinity for water and hydrophobic groups that do not exhibit an affinity for water; in other words, surfactant molecules have an amphiphilic structure. As a result, surfactants can form self-organizing molecular clusters called micelles in a solution (water or oil phase) and adsorb to the interface between the solution and the other phase (gas / solid).

[0204] Preferably, at least one surfactant in the additive coating is a nonionic surfactant. A nonionic surfactant is a surfactant that does not dissociate into ions in aqueous solution. This is in contrast to an ionic surfactant.

[0205] At least one surfactant advantageously provides an additional active functional group that may be particularly effective in capturing certain gaseous compounds generated from the aerosol-generating substrate. Furthermore, similar to that described above in relation to acetylated starch, it is understood that the inclusion of at least one surfactant further influences the wettability of the paper material.

[0206] The additive coating preferably contains at least 0.1 weight percent of at least one surfactant, more preferably at least 0.2 weight percent of at least one surfactant, more preferably at least 0.5 weight percent of at least one surfactant, and more preferably at least 1 weight percent of a surfactant, on a dry weight basis.

[0207] The additive coating preferably contains at least one surfactant in an amount of up to 5 weight percent, more preferably up to 3 weight percent, and more preferably up to 2 weight percent, on a dry weight basis.

[0208] For example, the additive coating may contain at least one surfactant in an amount of 0.1% to 5% by weight, or at least one surfactant in an amount of 0.1% to 3% by weight, or at least one surfactant in an amount of 0.1% to 2% by weight, or at least one surfactant in an amount of 0.2% to 5% by weight, or at least one surfactant in an amount of 0.2% to 3% by weight, or at least one surfactant in an amount of 0.2% to 2% by weight, or at least one surfactant in an amount of 0.5% to 5% by weight, or at least one surfactant in an amount of 0.5% to 3% by weight, or at least one surfactant in an amount of 0.5% to 2% by weight, or at least one surfactant in an amount of 1% to 5% by weight, or at least one surfactant in an amount of 1% to 3% by weight, or at least one surfactant in an amount of 1% to 2% by weight.

[0209] The cellulose-based filter material preferably contains at least 0.05% by weight of at least one surfactant, more preferably at least 0.1% by weight of at least one surfactant, more preferably at least 0.2% by weight of at least one surfactant, and more preferably at least 0.25% by weight of at least one surfactant, on a dry weight basis.

[0210] The cellulose-based filter material preferably contains at least one surfactant in a maximum of 2 weight percent, more preferably 1.5 weight percent, more preferably 1 weight percent, and more preferably 0.5 weight percent, on a dry weight basis.

[0211] For example, the cellulose-based filter material may contain at least one surfactant in an amount of 0.05 to 2 weight percent, or at least one surfactant in an amount of 0.05 to 1 weight percent, or at least one surfactant in an amount of 0.05 to 1.5 weight percent, or at least one surfactant in an amount of 0.05 to 2 weight percent, or at least one surfactant in an amount of 0.1 to 2 weight percent, or at least one surfactant in an amount of 0.1 to 1 weight percent, or at least one surfactant in an amount of 0.1 to 1.5 weight percent, or at least one surfactant in an amount of 0.1 to 2 weight percent, or at least one surfactant in an amount of 0.2 to 2 weight percent, or at least one surfactant in an amount of 0.2 to 1 weight percent, or at least one surfactant in an amount of 0.25 to 2 weight percent, or at least one surfactant in an amount of 0.25 to 1.5 weight percent, or at least one surfactant in an amount of 0.25 to 2 weight percent.

[0212] The weight ratio of at least one surfactant to exogenous polysaccharide in the additive coating is preferably at least 0.01, more preferably at least 0.02, more preferably at least 0.05, and more preferably at least 0.1. The weight ratio of at least one surfactant to exogenous polysaccharide in the additive coating may be up to 0.25.

[0213] The weight ratio of at least one surfactant to the additive for reducing phenol in the additive coating is preferably at least 0.02, more preferably at least 0.05, more preferably at least 0.1, and more preferably at least 0.15. The weight ratio of at least one surfactant to exogenous polysaccharide in the additive coating may be up to 0.375.

[0214] The additive coating may be applied to the paper material in any suitable manner.

[0215] The additive coating is preferably applied to the paper material before the paper material is formed inside the plug element.

[0216] Accordingly, as described above, the present invention further provides a method for producing a cellulosic filtration material for forming a plug element of an aerosol generating article according to the present invention. The method includes the steps of: providing a paper material; forming an additive coating solution containing at least one exogenous polysaccharide and an additive for reducing phenol; applying the additive coating solution to the paper material; drying and optionally curing the coated paper material; and forming a plug element containing the coated paper material. The content of at least one exogenous polysaccharide in the plug element is at least 5% by weight on a dry weight basis.

[0217] The additive coating solution is formed by combining the dry components of the additive coating and dispersing or dissolving them in water. The dry components include at least one exogenous polysaccharide, an additive for reducing phenol, and optionally one or more of the additional compounds mentioned above. The additive coating solution may optionally be heated before being applied to the paper material, for example, to induce the necessary reactions between the components of the additive coating.

[0218] For example, in the process of applying an additive coating solution to a paper material, the additive coating solution may be applied to the paper material (typically in sheet form) by a well-known printing process such as gravure printing or flexographic printing, or by a well-known coating process such as curtain coating, reverse gravure, semi-flexographic, rod coating, blade coating, comma coating, or slot die coating. These processes can advantageously enable the formation of a defined layer of additive coating on at least a portion of the outer surface of one or both sides of the paper material.

[0219] The additive coating solution may also be applied to the paper material (typically in sheet form) by an impregnation process, either by immersing the paper material in a bath of the additive coating or by spraying the additive coating solution onto the paper material, causing the additive coating solution to be absorbed at least partially into the paper material. Depending on the degree to which the paper material is hydrophilic or hydrophobic, the additive coating solution may penetrate more or less into the paper material, or a greater or less deposit of the additive coating may form on the outer surface of at least one side of the paper material.

[0220] Alternatively, in the process of applying the additive coating solution to the paper material, the additive coating solution may be applied to the paper material by injecting the additive coating solution into the plug element after the paper material has been processed and formed into a rod shape, or by immersing the formed plug element in a bath of the additive coating solution.

[0221] After the additive coating is applied to the paper material, the thus treated paper material is preferably dried by any suitable means, including conventional heating or microwave heating. Any curing of the additive coating may also be carried out during this drying process.

[0222] The drying step of the coated paper material, which may optionally include curing the coated paper material, may include heating the coated paper material using a conventional heater. Alternatively, or additionally, the drying step of the coated paper material, and optionally curing step, may include heating the coated paper material by microwave heating. Drying and optional curing of the additive coating solution is carried out to evaporate water from the solution and result in curing of the additive coating or curing of the additive coating, or both.

[0223] Methods for forming sheets of paper material into rod-shaped plug elements are generally known to those skilled in the art and may involve assembling or winding the sheet material.

[0224] In the aerosol generating article according to the present invention, the downstream element preferably comprises a plug element of the cellulose-based filter material described above, surrounded by a wrapper, such as a paper wrapper.

[0225] For example, a continuous web of paper material coated with an additive (i.e., a continuous web of processed paper material) may be drawn and passed between overlapping embossing or crimping rolls.

[0226] The textured web resulting from the processed paper material is preferably not moistened before being assembled and compressed laterally (for example, when being supplied into a forming cone, such as one used in a cigarette manufacturing machine). Some existing manufacturing processes involve a wetting step in which water is sprayed onto the paper material for use in aerosol-generating articles. However, in the context of the present invention, such a wetting step is preferably avoided because the addition of water can recrystallize the cellulose in the paper material, and therefore reduce the plug element's ability to absorb flue gas and phenol.

[0227] The paper wrapper may be rolled around the assembled and compressed web within the forming cone, and the overlapping edges of the paper wrapper may be joined together by applying adhesive to the first edge of the wrapper and then folding the other edge into contact with the first edge. The overlapping edges of the paper wrapper are joined together by a heated roller to remove any liquid and allow the adhesive to harden. The resulting rod may be cut into segments of a predetermined length by a rotary cutter.

[0228] The wrapper surrounding the cellulosic filter material may have a basis weight of at least 50 grams / square meter (gsm). If the downstream element is located at the downstream end of the aerosol-generating article, this may help provide the aerosol-generating article with the desired rigidity. In certain embodiments, it may be desirable to use a rigid wrapper, for example, a wrapper having a basis weight of at least about 80 grams / square meter (gsm), or at least about 100 gsm, or at least about 110 gsm.

[0229] The downstream element containing the cellulosic filtration material preferably has an average radial hardness of at least 75 percent, more preferably at least 80 percent, and more preferably at least 85 percent. The downstream element preferably has a radial hardness of less than 100 percent, and more preferably less than 95 percent. This makes it possible to provide an aerosol-generating article with a downstream end having a hardness satisfactory to consumers.

[0230] As used herein, the term “radial hardness” refers to resistance to compression in a direction transverse to the longitudinal axis. The radial hardness of an aerosol-generating article around a filter can be determined by applying a load across the article at the filter's location in a direction transverse to the article's longitudinal axis, and by measuring the average (mean) of the compressed diameter of the article. Radial hardness is given by:

number

[0231] To measure the hardness of a portion of an aerosol-generating article (such as a filter), the articles must be aligned parallel to each other in a plane, and a constant load must be applied to the same portion of each article being tested for a set period of time. This test is performed using the well-known DD60A Densimeter (manufactured and commercially available by Heinr. Borgwaldt GmbH (Germany)), which is equipped with a measuring head for aerosol-generating articles such as cigarettes and comes with an aerosol-generating article container.

[0232] The standard operating procedure for such a device involves applying an overall load of 2 kg for 20 seconds. After 20 seconds (while the load is still applied to the smoking article), the pressure on the load-applying cylindrical rod is determined and then used to calculate the hardness from the above equation. The temperature is maintained within the range of 22 degrees Celsius ± 2 degrees. The above test is called the DD60A test. The standard method for measuring filter hardness is performed while the aerosol-generating article is still unconsumed. Additional information regarding the measurement of mean radial hardness can be found, for example, in U.S. Patent Application No. 2016 / 0128378.

[0233] As mentioned above, downstream elements containing cellulosic filtration materials offer the advantage of improved biodegradability compared to conventional cellulose acetate segments.

[0234] The downstream element preferably contains substantially no cellulose acetate.

[0235] As briefly described above, the downstream element, which includes a plug element, is provided downstream of the aerosol generating substrate and aligned axially with the aerosol generating substrate.

[0236] In some embodiments, the aerosol generating article is essentially formed from an aerosol generating substrate and the aforementioned downstream elements provided in a configuration that abuts against a rod of the aerosol generating substrate. For example, the aerosol generating substrate may be in the form of a cylindrical rod of finely chopped tobacco material surrounded by a wrapper, and the downstream elements may be attached to a rod wrapped in a strip of chipping paper to form a mouthpiece of the aerosol generating article.

[0237] In other embodiments, the aerosol-generating article comprises one or more additional elements provided downstream of the aerosol-generating substrate and axially aligned with the aerosol-generating substrate. The downstream elements, comprising a plug element and any further elements provided downstream of the aerosol-generating substrate and axially aligned with the aerosol-generating substrate, form the downstream section of the aerosol-generating article.

[0238] In some preferred embodiments, the downstream element comprising the plug element is a mouthpiece element.

[0239] The aerosol generating article may be equipped with a mouthpiece at its downstream end, oral end, or proximal end, and the mouthpiece consists only of a plug element.

[0240] Alternatively, the aerosol generating article may be provided with a mouthpiece at its downstream, oral, or proximal end, the mouthpiece comprising a plug element and one or more further elements aligned axially in a mutually contacting end-to-end relationship. The plug element and the one or more further elements may be formed of the same material. Alternatively, the one or more further elements may be formed of a material other than that of the plug element.

[0241] The parameters or characteristics described herein with respect to a plug element used as the sole component of a mouthpiece may be equally applicable to a plug element used as one of multiple components of a mouthpiece.

[0242] Advantageously, the aerosol generating article according to the present invention, in which the downstream element is a mouthpiece element, provides an acceptable visual and tactile experience for the consumer thanks to the density and rigidity of the plug element. Furthermore, in the aerosol generating article according to the present invention, in which the downstream element is a mouthpiece element, the cellulosic filtration material can efficiently reduce undesirable compounds (e.g., phenol) from the aerosol generated from the substrate, with little to no effect on the taste perceived by the consumer during use of the aerosol generating article. Thus, the aerosol generating article according to the present invention, in which the plug element is a mouthpiece element, provides a more sustainable alternative to aerosol generating articles containing a cellulose acetate filter segment as the mouthpiece filter segment.

[0243] Mouthpiece elements may have low or virtually no particle phase filtration efficiency. While they can prevent substrate material from the aerosol-generating substrate from reaching the consumer's mouth during use, mouthpiece elements with low particle phase filtration efficiency have less impact on the delivery of aerosol species to the consumer. This is particularly advantageous in aerosol-generating articles where the aerosol-generating substrate is heated rather than burned.

[0244] In a preferred embodiment, the particle phase filtration efficiency of the plug element is less than about 30 percent, and more preferably less than about 20 percent.

[0245] In some embodiments, the mouthpiece element may have an RTD of about 25 mmH2O or less, about 20 mmH2O or less, or about 15 mmH2O or less. In such embodiments, the mouthpiece element may have an RTD of at least about 10 mmH2O.

[0246] The mouthpiece element may have an RTD of approximately 10 mmH2O to 25 mmH2O, approximately 10 mmH2O to 20 mmH2O, or approximately 10 mmH2O to 15 mmH2O.

[0247] The mouthpiece element preferably has a substantially circular cross-section.

[0248] Preferably, the mouthpiece element has substantially the same outer diameter as the outer diameter of the aerosol-generating article.

[0249] The length of the mouthpiece element may be at least approximately 3 millimeters, or at least approximately 5 millimeters.

[0250] The length of the mouthpiece element may be approximately 11 millimeters or less, or approximately 9 millimeters or less.

[0251] The length of the mouthpiece element may be approximately 3 mm to 11 mm, or approximately 3 mm to 9 mm.

[0252] The length of the mouthpiece element may be approximately 5 mm to 11 mm, or approximately 5 mm to 9 mm.

[0253] For example, the length of the mouthpiece element may be approximately 7 millimeters.

[0254] The length of the mouthpiece element may be selected based on the desired overall length of the aerosol-generating article.

[0255] The mouthpiece element may be surrounded by a plug wrap.

[0256] The mouthpiece element may not be ventilated to prevent air from entering the aerosol-generating item along the mouthpiece element.

[0257] The mouthpiece element may be connected by a chipping wrapper to one or more adjacent components of the aerosol-generating article.

[0258] The aerosol generating article may have an oral end cavity defined at its downstream end. For example, the mouthpiece element itself may be in the form of a hollow tubular element. Alternatively, the mouthpiece may include the aforementioned non-hollow plug element immediately upstream of the hollow tubular segment provided at the downstream end of the mouthpiece. As a further alternative, the oral end cavity may be defined by an outer wrapper of the mouthpiece extending beyond the downstream end of the aforementioned plug element.

[0259] In some embodiments, the plug element may be an additional element provided downstream of the aerosol generating substrate other than the mouthpiece element. That is, the aerosol generating article comprises a mouthpiece, and the plug element is provided between the aerosol generating substrate and the mouthpiece of the aerosol generating article.

[0260] For example, the downstream element may be a support element provided immediately downstream of the aerosol generating substrate, preferably adjacent to the aerosol generating substrate. One such support element is adapted to provide structural strength to the aerosol generating article. The support element is advantageously configured to prevent the aerosol generating substrate from moving downstream when the heating element of the aerosol generating device is inserted into the aerosol generation.

[0261] In some embodiments, a downstream element comprising a plug element may form part of an aerosol cooling element provided downstream of the aerosol generating substrate, which is adapted to facilitate the cooling of aerosols generated during use of the aerosol generating article before reaching the downstream end of the aerosol generating article.

[0262] The aerosol cooling element preferably has low draw resistance. That is, the aerosol cooling element preferably provides low resistance to the air passage through the aerosol generating article. It is preferable that the aerosol cooling element does not substantially affect the draw resistance of the aerosol generating article.

[0263] The aerosol cooling element may comprise multiple channels extending along its longitudinal axis. These multiple longitudinal channels may be defined by sheets of paper material that have undergone one or more of the following processes: crimping, pleating, gathering, and folding, to form the channels. Alternatively, the multiple longitudinal channels may be defined by a single sheet that has undergone one or more of the following processes: crimping, pleating, gathering, and folding, to form the multiple channels. Alternatively, the multiple longitudinal paths may be defined by multiple sheets that have undergone one or more of the following processes: crimping, pleating, gathering, and folding, to form the multiple paths.

[0264] For example, the aerosol cooling element may be formed from an aggregate of paper material sheets having a specific surface area of ​​approximately 10 square millimeters / milligram to approximately 100 square millimeters / milligram. In some embodiments, the aerosol cooling element may be formed from an aggregate of paper material sheets having a specific surface area of ​​approximately 35 square millimeters / milligram.

[0265] At least one of the support element and the aerosol cooling element may be in the form of a hollow tubular element. In some embodiments, both the support element and the aerosol cooling element are in the form of a hollow tubular element, which may differ in length, inner diameter, or both.

[0266] In the aerosol-generating articles according to the present invention, such hollow tubular elements provide an unrestricted flow channel. This means that the hollow tubular elements provide a negligible level of RTD. As used herein in relation to the present invention, the term “negligible level of RTD” is used to describe an RTD of less than 1 mmH2O per 10 mm of length of the hollow tubular substrate element, less than 0.4 mmH2O per 10 mm of length of the hollow tubular substrate element, or less than 0.1 mmH2O per 10 mm of length of the hollow tubular substrate element. Therefore, the flow channel should not contain any components that would obstruct the airflow in the longitudinal direction. Preferably, the flow channel is substantially empty.

[0267] The hollow tubular element may have an overall length of at least about 10 millimeters, at least about 12 millimeters, or at least about 15 millimeters.

[0268] The hollow tubular element may have a total length of approximately 30 mm or less, 25 mm or less, or approximately 23 mm or less.

[0269] The hollow tubular element may have an overall length of approximately 10 mm to 30 mm, approximately 10 mm to 25 mm, or approximately 10 mm to 23 mm. The hollow tubular element may have an overall length of approximately 12 mm to 30 mm, approximately 12 mm to 25 mm, or approximately 12 mm to 23 mm. The hollow tubular element may have an overall length of approximately 12 mm to 30 mm, approximately 12 mm to 25 mm, or approximately 12 mm to 23 mm.

[0270] The total length of the hollow tubular element may be selected based on the desired total length of the aerosol-generating article.

[0271] In some embodiments, the ventilation zone may be provided downstream of the aerosol generating substrate.

[0272] For example, cooling of the smoke flow generated during the combustion of an aerosol-generating substrate can be achieved by providing a ventilation zone along the mouthpiece of the aerosol-generating article.

[0273] In another embodiment, satisfactory cooling of the aerosol flow generated upon heating of the aerosol-generating substrate and drawn out through the aforementioned hollow tubular element can be achieved by providing a ventilation zone positioned along the hollow tubular element itself. While we do not wish to be bound by theory, the temperature reduction resulting from introducing cooler outside air into the aerosol-generating article downstream of the aerosol-generating element through the ventilation zone may have a favorable effect on the nucleation and growth of aerosol particles.

[0274] The ventilation zone may include, for example, a plurality of perforations provided through the tubular wall of a hollow tubular element. The ventilation zone may comprise at least one row of circumferential perforations. The ventilation zone may comprise two rows of periphery perforations. For example, the perforations may be formed online during the manufacture of the aerosol-generating article. Each circumferential row of perforations comprises 8 to 30 perforations.

[0275] In some embodiments, the downstream section of the aerosol generating article may comprise, in a continuous order, a support element, an aerosol cooling element, and a mouthpiece. Preferably, one or more of the support element, aerosol cooling element, and mouthpiece are in the form of the plug element described above.

[0276] In some embodiments, the aerosol-generating article comprises an upstream section located upstream of the aerosol-generating substrate. The upstream section is preferably located immediately upstream of the aerosol-generating substrate. The upstream section preferably extends from the upstream end of the aerosol-generating article to the upstream end of the aerosol-generating substrate. The upstream section preferably comprises an upstream element located immediately upstream of the rod of the aerosol-generating substrate.

[0277] If the aerosol-generating substrate contains shredded tobacco, such as tobacco cut filler, the upstream section or its components may additionally help prevent the loss of loose tobacco particles from the upstream end of the article.

[0278] The upstream section or its upstream element may also provide some degree of additional protection to the aerosol-generating substrate during storage, by covering at least to some extent the upstream end of the aerosol-generating substrate which may otherwise be exposed. In the case of an aerosol-generating article intended to be inserted into a cavity in an aerosol generator so that the aerosol-generating substrate can be externally heated within the cavity, the upstream section or its upstream element may advantageously facilitate the insertion of the upstream end of the article into the cavity.

[0279] The upstream elements of the upstream section may be made of any material suitable for use in an aerosol generating article. The upstream elements may be made of the same material as those used for one of the other components of an aerosol generating article, such as a mouthpiece, aerosol cooling element, or support element, whose shape and function are described above. Suitable materials for the upstream elements include filter materials, ceramics, polymer materials, cellulose acetate, cardboard, zeolites, or aerosol generating substrates.

[0280] In a preferred embodiment, the upstream element may comprise a plug element comprising a cellulosic filter material including a paper material and an additive coating applied to the paper material, wherein the additive coating contains at least 5% by weight of exogenous lignin on a dry weight basis, and the overall lignin content in the plug element is at least 2% by weight of the plug element.

[0281] For example, the upstream element may be formed from the same cellulosic filtration material as the downstream element described above. From an environmental standpoint, this is advantageous in that the majority of the aerosol-generating article as a whole is more easily decomposable. Furthermore, from a manufacturing standpoint, it is advantageous to form different components of the same aerosol-generating article from the same material, as this generally requires less adjustment to the settings of existing equipment.

[0282] The upstream section or its upstream element preferably has an outer diameter approximately equal to the outer diameter of the aerosol-generating article. Preferably, the outer diameter of the upstream section or its upstream element is about 6 mm to about 8 mm, and more preferably about 7 mm to about 7.5 mm. Preferably, the upstream section or its upstream element has an outer diameter of about 7.1 mm.

[0283] Preferably, the upstream section or upstream element has a length of about 2 mm to about 8 mm, more preferably about 3 mm to about 7 mm, and more preferably about 4 mm to about 6 mm. In a particularly preferred embodiment, the upstream section or upstream element has a length of about 5 mm. The length of the upstream section or upstream element can be advantageously varied to provide the desired total length of the aerosol-generating article.

[0284] The upstream section is preferably surrounded by a wrapper such as a plug wrap. The wrapper surrounding the upstream section may be a rigid plug wrap, for example, a plug wrap having a basis weight of at least about 80 grams / square meter (gsm), or at least about 100 gsm, or at least about 110 gsm. This improves the structural rigidity of the upstream section.

[0285] The upstream section is preferably connected by an outer wrapper to the rods of the aerosol generating substrate and, optionally, to at least a portion of the downstream section.

[0286] The aerosol-generating article may also be a combustible smoking article. A combustible smoking article typically comprises a cylindrical rod of tobacco cut filler enclosed in a paper wrapper, and a cylindrical filter aligned axially with the wrapped tobacco rod, with its ends in contact in most cases. The cylindrical filter typically comprises one or more plug elements of fibrous filter material enclosed in a paper plug wrapper. The rolled tobacco rod and the filter are usually joined by a strip of chipping wrapper that encloses the entire length of the filter and adjacent portions of the rolled tobacco rod. In the combustible smoking article according to the present invention, the cylindrical filter comprises a downstream element including plug elements having the characteristics described above.

[0287] The aerosol generating article may be an aerosol generating article (heat-activated aerosol generating article) that generates an aerosol when heated. A heat-activated aerosol generating article typically comprises a cylindrical rod of an aerosol generating substrate surrounded by a paper wrapper, and a downstream section of the aerosol generating substrate downstream of the rod. The downstream section typically comprises at least one hollow tubular element immediately downstream of the rod of the aerosol generating substrate, and a mouthpiece.

[0288] The aerosol-generating article preferably has an overall length of 40 mm to 80 mm, or 40 mm to about 70 mm, or 40 mm to about 60 mm, or 45 mm to about 80 mm, or about 45 mm to about 70 mm, or 45 mm to about 60 mm, or 50 mm to 80 mm, or 50 mm to about 70 mm, or about 50 mm to about 60 mm. In an exemplary embodiment, the overall length of the aerosol-generating article is about 45 mm.

[0289] The aerosol-generating article preferably has a substantially circular cross-section.

[0290] The aerosol-generating article preferably has an outer diameter of from about 5 millimeters to about 12 millimeters, or from about 6 millimeters to about 12 millimeters, or from about 7 millimeters to about 12 millimeters, or from about 5 millimeters to about 10 millimeters, or from about 6 millimeters to about 10 millimeters, or from about 7 millimeters to about 10 millimeters, or from about 5 millimeters to about 8 millimeters, or from about 6 millimeters to about 8 millimeters, or from about 7 millimeters to about 8 millimeters. In other embodiments, the aerosol-generating article has an outer diameter of less than 7 millimeters.

[0291] The overall RTD of the aerosol-generating article is preferably at least 10 millimeters H2O, more preferably at least 15 millimeters H2O, more preferably at least 20 millimeters H2O, more preferably at least 25 millimeters H2O, more preferably at least 30 millimeters H2O.

[0292] The overall RTD of the aerosol-generating article is preferably 70 millimeters H2O or less, more preferably 60 millimeters H2O or less, more preferably 55 millimeters H2O or less, more preferably 50 millimeters H2O or less, more preferably 45 millimeters H2O or less.

[0293] For example, the overall RTD of the aerosol-generating article can be from 10 millimeters H2O to 70 millimeters H2O, or from 15 millimeters H2O to 60 millimeters H2O, or from 20 millimeters H2O to 55 millimeters H2O, or from 25 millimeters H2O to 45 millimeters H2O, or from 30 millimeters H2O to 45 millimeters H2O.

[0294] As described above, the aerosol-generating article according to the present invention comprises an aerosol-generating substrate. In some embodiments, the aerosol-generating article comprises a rod of the aerosol-generating substrate surrounded by a rod plug wrap.

[0295] Preferably, the rod of the aerosol generating substrate has a length of at least 8 millimeters, more preferably has a length of at least 9 millimeters, and even more preferably has a length of at least 10 millimeters. Preferably, the length of the rod of the aerosol generating substrate is less than 16 millimeters, more preferably less than 15 millimeters, and even more preferably less than 14 millimeters. For example, the rod of the aerosol generating substrate can have a length of 8 millimeters to 16 millimeters, or 9 millimeters to 15 millimeters, or 10 millimeters to 14 millimeters. In a particularly preferred embodiment, the rod of the aerosol generating substrate has a length of about 12 millimeters.

[0296] The ratio of the length of the rod of the aerosol generating substrate to the total length of the aerosol generating article is preferably at least 0.10, more preferably at least 0.15, more preferably at least 0.20, and even more preferably at least 0.25. Preferably, the ratio of the length of the rod of the aerosol generating substrate to the total length of the aerosol generating article is less than 0.50, more preferably less than 0.45, more preferably less than 0.40, and even more preferably less than 0.35. For example, the ratio of the length of the rod of the aerosol generating substrate to the total length of the aerosol generating article may be 0.1 to 0.5, or 0.15 to 0.45, or 0.2 to 0.4, or 0.25 to 0.35.

[0297] The rod of the aerosol generating substrate preferably has an outer diameter substantially equal to the outer diameter of the aerosol generating article.

[0298] Preferably, the rod of the aerosol generating substrate has an outer diameter of at least 5 mm, more preferably at least 6 mm, and more preferably at least 7 mm. Preferably, the rod of the aerosol generating substrate has an outer diameter of less than 12 mm, more preferably less than 10 mm, and more preferably less than 8 mm. For example, the outer diameter may be between 5 mm and 12 mm, or between 6 mm and 10 mm, or between 7 mm and 8 mm. In a particularly preferred embodiment, the rod of the aerosol generating substrate has an outer diameter of about 7.1 mm.

[0299] The rod of the aerosol generating substrate preferably has a substantially uniform cross-section along its length. It is particularly preferable that the rod of the aerosol generating substrate has a substantially circular cross-section.

[0300] The aerosol-generating substrate may have a density of at least about 150 milligrams / cubic centimeter, at least about 175 milligrams / cubic centimeter, at least about 200 milligrams / cubic centimeter, or at least or about 250 milligrams / cubic centimeter.

[0301] The aerosol generating substrate may have a density of approximately 500 milligrams / cubic centimeter or less, approximately 450 milligrams / cubic centimeter or less, approximately 400 milligrams / cubic centimeter or less, or approximately 350 milligrams / cubic centimeter or less.

[0302] The RTD of the aerosol generating substrate rod may be at least about 4 mmH2O, at least about 5 mmH2O, or at least about 6 mmH2O.

[0303] The RTD of the aerosol generating substrate rod may be approximately 10 mmH2O or less, approximately 9 mmH2O or less, or approximately 8 mmH2O or less.

[0304] The aerosol generating substrate may be a solid aerosol generating substrate. Suitable types of materials for use in the aerosol generating substrate are described below and include, for example, homogenized tobacco materials such as tobacco cut filler and cast leaf, aerosol generating films, and gel compositions.

[0305] The aerosol generating substrate preferably includes an aerosol-forming agent. Suitable aerosol-forming agents include, for example, polyhydric alcohols (e.g., triethylene glycol, 1,3-butanediol, propylene glycol, glycerin, etc.), esters of polyhydric alcohols (e.g., glycerol mono-, di-, or triacetate, etc.), aliphatic esters of mono-, di-, or polycarboxylic acids (e.g., dimethyl dodecanediate, dimethyl tetradecanediate, etc.), and combinations thereof.

[0306] The aerosol-forming body preferably contains one or more of glycerin and propylene glycol. The aerosol-forming body may consist of glycerin, propylene glycol, or a combination of glycerin and propylene glycol.

[0307] In certain embodiments, the aerosol generating substrate preferably contains at least 5 weight percent of aerosol-forming material on a dry weight basis of the aerosol generating substrate, more preferably at least 10 weight percent on a dry weight basis, and even more preferably at least 15 weight percent on a dry weight basis. In such embodiments, the aerosol generating substrate preferably contains 30 weight percent or less of aerosol-forming material on a dry weight basis of the aerosol generating substrate, more preferably 25 weight percent or less on a dry weight basis, and more preferably 20 weight percent or less on a dry weight basis. For example, the aerosol-forming material content of the aerosol generating substrate may be 5 weight percent to 30 weight percent, or 10 weight percent to 25 weight percent, or about 15 weight percent to about 20 weight percent on a dry weight basis. Therefore, in such embodiments, the aerosol-forming material content is relatively low.

[0308] In other embodiments, the aerosol generating substrate preferably contains at least 40 weight percent of aerosol forming material on a dry weight basis of the aerosol generating substrate, more preferably at least 45 weight percent on a dry weight basis, and more preferably at least 50 weight percent on a dry weight basis. In such embodiments, the aerosol generating substrate preferably contains 80 weight percent or less of aerosol forming material on a dry weight basis of the aerosol generating substrate, more preferably 75 weight percent or less on a dry weight basis, and more preferably 70 weight percent or less on a dry weight basis. For example, the aerosol forming material content of the aerosol generating substrate may be 40 weight percent to 80 weight percent, or 45 weight percent to 75 weight percent, or 50 weight percent to 70 weight percent on a dry weight basis. Therefore, in such embodiments, the aerosol forming material content is relatively high.

[0309] In some preferred embodiments, the aerosol generating substrate includes tobacco material. For example, the aerosol generating substrate may include shredded tobacco material. For example, the shredded tobacco material may be in the form of cut fillers, as will be described in more detail below. Alternatively, the shredded tobacco material may be in the form of shredded sheets of homogenized tobacco material. Preferred homogenized tobacco materials for use in the present invention are described below.

[0310] In the context of this specification, the term “cut filler” is used to refer to a blend of shredded plant material, such as tobacco plant material comprising one or more of the following: leaf laminas, processed stems and veins, and homogenized plant material.

[0311] The cut filler suitable for use in the present invention may generally be similar to the cut filler used in conventional smoking articles. The cutting width of the cut filler may preferably be 0.3 mm to 2.0 mm, or 0.5 mm to 1.2 mm, or 0.6 mm to 0.9 mm.

[0312] Preferably, the strands have a length of from about 10 millimeters to about 40 millimeters, and then the strands are arranged to form the rod of the aerosol generating substrate.

[0313] The cut filler is preferably impregnated with an aerosol former. The impregnation of the cut filler can be carried out by spraying or by other suitable application methods. Preferably, the aerosol former in the cut filler comprises one or more of glycerol and propylene glycol. The aerosol former may consist of glycerol, or propylene glycol, or a combination of glycerol and propylene glycol.

[0314] In another preferred embodiment, the aerosol generating substrate comprises a homogenized plant material, preferably a homogenized tobacco material.

[0315] As used herein, the term "homogenized plant material" encompasses any plant material formed by the aggregation of plant particles. For example, a sheet or web consisting of a homogenized tobacco material for the aerosol generating substrate of the present invention may be formed by aggregating tobacco material particles obtained by crushing, grinding or pulverizing plant material and optionally one or more of a thin layer of tobacco leaves and the stem of tobacco leaves. The homogenized plant material can be produced by molding, extrusion, a papermaking process, or any other suitable process known in the art.

[0316] The homogenized plant material can be provided in any suitable form.

[0317] In some embodiments, the homogenized plant material may be in the form of one or more sheets. As used herein in relation to the present invention, the term "sheet" refers to a layered element having a width and length substantially greater than its thickness.

[0318] The homogenized plant material may be in the form of multiple pellets or granules.

[0319] Homogenized plant material may be in the form of multiple strands, strips, or shreds. As used herein, the term “strand” refers to an elongated element of the material having a length substantially greater than its width and thickness.

[0320] The aerosol-forming content of the homogenized tobacco material is preferably within the range defined above for aerosol-generating substrates having a relatively low aerosol-forming content.

[0321] In other 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 water, preferably less than 30% by weight.

[0322] 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.

[0323] In the context of the present invention, the term "cellulose-based film-forming agent" is used to refer to a cellulose polymer having the ability to form a continuous film, either by itself or in the presence of an auxiliary thickener. Preferably, the cellulose-based film-forming agent is selected from the group consisting of hydroxypropyl methylcellulose (HPMC), methylcellulose (MC), ethylcellulose (EC), hydroxyethyl methylcellulose (HEMC), hydroxyethylcellulose (HEC), hydroxypropylcellulose (HPC), and combinations thereof. In a particularly preferred embodiment, the cellulose-based film-forming agent is HPMC.

[0324] The aerosol-forming material content of the aerosol-generating film is within the range defined above for aerosol-generating substrates having a relatively high aerosol-forming material content.

[0325] Suitable aerosol-generating films for use as an aerosol-generating substrate for an aerosol-generating article according to the present invention are described in WO-A-2020 / 207733 and WO-A-2022 / 074157.

[0326] Preferably, the aerosol generating film contains 0.5% to 10% by weight of nicotine, or 1% to about 8% by weight of nicotine, or about 2% to about 6% by weight of nicotine, on a dry weight basis.

[0327] The aerosol generating film may be a substantially tobacco-free aerosol generating film.

[0328] In alternative embodiments of the present invention, the aerosol-generating substrate may include a gel composition comprising nicotine, at least one gelling agent, and an aerosol-forming body. The gel composition is preferably substantially free of tobacco.

[0329] The preferred weight range of nicotine in the gel composition is the same as that defined above in relation to the aerosol generating film.

[0330] A suitable gel composition for use as an aerosol generating substrate for an aerosol generating article according to the present invention is described in WO-A-2021 / 170642.

[0331] The gel composition preferably contains at least 50 weight percent, more preferably at least 60 weight percent, and more preferably at least 70 weight percent, of aerosol-forming material on a dry weight basis. The gel composition may contain up to 80 weight percent of aerosol-forming material. The aerosol-forming material in the gel composition is preferably glycerol.

[0332] In certain embodiments of the present invention, the aerosol generating article further includes one or more elongated susceptor elements within a rod of the aerosol generating substrate. For example, one or more elongated susceptor elements may be arranged substantially along their longitudinal axis within the aerosol generating rod and may be in thermal contact with the aerosol generating substrate.

[0333] As used herein in relation to the present invention, the term "susceptor element" refers to a material capable of converting electromagnetic energy into heat.

[0334] Suitable susceptor elements for use in the aerosol generating substrate of the aerosol generating article according to the present invention are described in WO-A-2021 / 170673.

[0335] Preferably, the rod of the aerosol generating substrate is surrounded by a wrapper. The wrapper may be a paper wrapper or a non-paper wrapper.

[0336] Suitable paper wrappers for use in specific embodiments of the present invention are known in the art and include, but are not limited to, cigarette papers and filter plug wrappers. Suitable non-paper wrappers for use in specific embodiments of the present invention are known in the art and include, but are not limited to, sheets of homogenized tobacco material.

[0337] According to a second aspect of the present invention, an aerosol generating system is provided comprising an aerosol generating article according to the first aspect of the present invention and an aerosol generating device configured to heat the aerosol generating substrate of the aerosol generating article.

[0338] The aerosol generator includes means for heating the aerosol generating substrate to a temperature sufficient to generate aerosols from the aerosol generating substrate. Preferably, the aerosol generator comprises a housing defining a cavity configured to receive an aerosol generating article, and means for heating the aerosol generating substrate to a temperature sufficient to generate aerosols from the aerosol generating substrate when the aerosol generating article is received in the cavity.

[0339] The aerosol generator may be a handheld aerosol generator. The aerosol generator may be an electrically operated aerosol generator. The aerosol generator may include a power supply and control electronics. The aerosol generator may include a battery and control electronics.

[0340] The aerosol generator may be configured to internally heat the aerosol generating substrate. That is, the aerosol generator may be configured to supply heat to the aerosol generating substrate from a position inside the aerosol generating article. For example, in some embodiments, the aerosol generator includes a heater element configured to be inserted into the aerosol generating element when the aerosol generating article is received in the cavity of the aerosol generator.

[0341] In other embodiments, the aerosol generating article comprises a susceptor element provided at a position within the aerosol generating element, and the aerosol generating device comprises an inductor coil located on or within the housing, and the power supply of the aerosol generating device is connected to the inductor coil and configured to supply a high-frequency oscillating current to the inductor coil. This generates an alternating magnetic field that induces a voltage within the susceptor element. The induced voltage causes a current to flow within the susceptor element, and this current causes Joule heating of the susceptor element, which then heats the aerosol generating substrate. The aerosol generating device may have the ability to generate 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.

[0342] The aerosol generator may be configured to externally heat the aerosol generating substrate. That is, the aerosol generator may be configured to supply heat to the aerosol generating substrate from a location outside the aerosol generating article. For example, in some embodiments, the aerosol generator includes a heater element located around the periphery of a cavity and configured to heat the aerosol generating substrate of the aerosol generating article from outside the aerosol generating element of the aerosol generating article. [Brief explanation of the drawing]

[0343] Here, we will further describe the embodiment with reference to the attached drawings.

[0344] [Figure 1] Figure 1 shows a schematic side cross-sectional view of an aerosol generating article according to an embodiment of the present invention. [Figure 2] Figure 2 shows a schematic side cross-sectional view of another aerosol generating article according to another embodiment of the present invention. [Figure 3] Figure 3 shows a schematic side cross-sectional view of another aerosol-generating article according to a further embodiment of the present invention. [Modes for carrying out the invention]

[0345] The aerosol generating article 1000 shown in Figure 1 comprises an aerosol generating element 1002 in the form of a substantially cylindrical rod 1004 of shredded tobacco surrounded by a paper wrapper 1006. Furthermore, the aerosol generating article 1000 comprises a substantially cylindrical mouthpiece 1008 including a segment 1010 of cellulosic filter material surrounded by a plug wrapper 1012.

[0346] The mouthpiece 1008 is attached to the aerosol generating element 1002 by a strip of chipping paper 1014. Perforations 1016 formed through the chipping paper and plug wrap are provided to allow aeration air into the segment 1010 when the consumer inhales the mouthpiece 1008 during use. The aerosol generating article 1000 has a length of 70 mm and an outer diameter of 7.6 mm.

[0347] Segment 1010 is in the form of a plug element comprising a paper material and an additive coating applied to the paper material, the additive coating comprising at least one exogenous polysaccharide and an additive for reducing phenol. The total content of exogenous polysaccharides in the plug element is at least 5 weight percent of the plug element.

[0348] The aerosol generating article 10 shown in Figure 2 comprises a rod 12 of an aerosol generating base 12 and a downstream section 14 located downstream of the rod 12 of the aerosol generating base. Furthermore, the aerosol generating article 10 includes an upstream section 16 located upstream of the rod 12 of the aerosol generating base. Thus, the aerosol generating article 10 extends from the upstream or distal end 18 to the downstream or oral end 20 and has an overall length of approximately 45 millimeters.

[0349] The downstream section 14 includes a support element 22 located immediately downstream of the rod 12 of the aerosol generating substrate, and the support element 22 is aligned with the rod 12 in the longitudinal direction. In the embodiment of Figure 2, the upstream end of the support element 18 abuts against the downstream end of the rod 12 of the aerosol generating substrate. In addition, the downstream section 14 includes an aerosol cooling element 24 located immediately downstream of the support element 22, and the aerosol cooling element 24 is aligned with the rod 12 and the support element 22 in the longitudinal direction. In the embodiment of Figure 1, the upstream end of the aerosol cooling element 24 abuts against the downstream end of the support element 22. In the embodiment of Figure 2, the support element 22 and the aerosol cooling element 24 together define the intermediate hollow section 50 of the aerosol generating article 10.

[0350] The support element 22 includes a first hollow tubular segment 26. The first hollow tubular segment 26 is provided in the form of a hollow cylindrical tube made of a filter material. The first hollow tubular segment 26 defines an internal cavity 28 that extends entirely from the upstream end 30 of the first hollow tubular segment 20 to the downstream end 32 of the first hollow tubular segment 20. The internal cavity 28 is substantially empty, and therefore substantially unlimited airflow is possible along the internal cavity 28.

[0351] The first hollow tubular segment 26 has a length of approximately 8 millimeters, an outer diameter of approximately 7.25 millimeters, and an inner diameter of approximately 1.9 millimeters. Therefore, the thickness of the peripheral wall of the first hollow tubular segment 26 is approximately 2.67 millimeters.

[0352] The aerosol cooling element 24 comprises a second hollow tubular segment 34. The second hollow tubular segment 34 is provided in the form of a hollow cylindrical tube made of a filter material. The second hollow tubular segment 34 defines an internal cavity 36 that extends all the way from the upstream end 38 of the second hollow tubular segment 34 to the downstream end 40 of the second hollow tubular segment 34. The internal cavity 36 is substantially empty, and therefore substantially unlimited airflow is possible along the internal cavity 36.

[0353] The second hollow tubular segment 34 has a length of approximately 8 millimeters, an outer diameter of approximately 7.25 millimeters, and an inner diameter of approximately 3.25 millimeters. Therefore, the thickness of the peripheral wall of the second hollow tubular segment 34 is approximately 2 millimeters. Thus, the ratio between the inner diameter of the first hollow tubular segment 26 and the inner diameter of the second hollow tubular segment 34 is approximately 0.75.

[0354] The aerosol-generating article 10 includes a ventilation zone 60 provided along the second hollow tubular segment 34. More specifically, the ventilation zone is provided approximately 2 millimeters from the upstream end of the second hollow tubular segment 34. The ventilation level of the aerosol-generating article 10 is approximately 25 percent.

[0355] In the embodiment shown in Figure 2, the downstream section 14 further comprises a mouthpiece element 42 located downstream of the intermediate hollow section 50. More specifically, the mouthpiece element 42 is positioned immediately downstream of the aerosol cooling element 24. As shown in the drawing of Figure 2, the upstream end of the mouthpiece element 42 abuts against the downstream end 40 of the aerosol cooling element 18.

[0356] The mouthpiece element 42 is provided in the form of a cylindrical plug element 44 comprising a paper material and an additive coating applied to the paper material, the additive coating comprising at least one exogenous polysaccharide and an additive for reducing phenol. The total content of exogenous polysaccharides in the plug element is at least 5 weight percent of the plug element.

[0357] The mouthpiece element 42 has a length of approximately 12 millimeters and an outer diameter of approximately 7.25 millimeters.

[0358] Rod 12 contains one of the aerosol-generating substrates of the type described above.

[0359] The rod 12 of the aerosol generating substrate has an outer diameter of approximately 7.25 millimeters and a length of approximately 12 millimeters.

[0360] The aerosol generating article 10 further comprises an elongated susceptor 46 within the rod 12 of the aerosol generating substrate. More specifically, the susceptor 46 is disposed substantially along the longitudinal axis within the aerosol generating substrate so as to be substantially parallel to the longitudinal axis of the rod 12. As shown in the drawing of Figure 2, the susceptor 46 is positioned radially centrally within the rod and extends effectively along the longitudinal axis of the rod 12. More specifically, the susceptor 46 is in thermal contact with the aerosol generating substrate. The susceptor 46 extends along the entire length of the rod 12 from the upstream end to the downstream end. In practice, the susceptor 46 has substantially the same length as the rod 12 of the aerosol generating substrate.

[0361] More specifically, in the embodiment shown in Figure 2, the susceptor 46 is provided in the form of a strip, having a length of about 12 millimeters, a thickness of about 60 micrometers, and a width of about 4 millimeters.

[0362] The upstream section 16 includes an upstream element 48 located immediately upstream of the rod 12 of the aerosol generating substrate, and the upstream element 48 is aligned with the rod 12 in the longitudinal direction. In the embodiment shown in Figure 2, the downstream end of the upstream element 48 abuts against the upstream end of the rod 12 of the aerosol generating substrate. This advantageously prevents the susceptor 46 from detaching. Furthermore, this ensures that consumers cannot accidentally come into contact with the heated susceptor 46 after use.

[0363] The upstream element 48 comprises a material segment 50 in the form of a cylindrical plug of filtration material and a first wrapper 52 surrounding the material segment 50. The material segment 50 has a length of approximately 5 millimeters. The RTD of the material segment 50 is approximately 30 millimeters of H2O.

[0364] The aerosol generating article 10 further comprises a coupling wrapper 54 that attaches the upstream element 48 to the remaining components of the aerosol generating article. In the embodiment shown in Figure 2, a single coupling wrapper 54 is illustrated that surrounds and holds together the upstream element 48, the rod 12, and the downstream section 14 to form the aerosol generating article.

[0365] However, it will be clear that alternative configurations are possible, employing two or more binding wrappers to assemble different components of the aerosol generating article. For example, a first binding wrapper can be used to attach the support element 22 to the aerosol cooling element 24, and the resulting assembly can then be attached to the upstream section 16 and rod 12 by a second binding wrapper. The resulting combination of components can then be attached to the mouthpiece element 42 by a chipping wrapper. As shown in the drawing of Figure 1, the aerosol generating article 10 further comprises a wrapper 70 surrounding the rod 12 of the aerosol generating substrate. The wrapper 70 is separate from and distinct from the first wrapper 52 surrounding the material segment 50. Neither the first wrapper 52 nor the wrapper 70 contains metal foil.

[0366] In the aerosol generating article 10 of Figure 2, one or more of the first hollow tubular segment 26 of the support element 22, the second hollow tubular segment 34 of the aerosol cooling element 24, and the material segment 50 of the upstream element 48 may be made of the same material according to the present invention used in the mouthpiece element 42.

[0367] The aerosol generating article 100 shown in Figure 3 comprises a rod of an aerosol generating substrate 112 and a downstream section 114 located downstream of the rod 112 of the aerosol generating substrate. Furthermore, the aerosol generating article 100 may include an upstream section 116. Thus, the aerosol generating article 100 extends from an upstream or distal end 118 substantially coinciding with the upstream end of the upstream section 116 to a downstream or oral end 120 coinciding with the downstream end of the downstream section 114. The downstream section 114 comprises a hollow tubular element 122 and a mouthpiece element 150. The upstream section 116 comprises an upstream plug element 124.

[0368] The aerosol generating article 10 has an overall length of approximately 45 mm and an outer diameter of approximately 7.2 mm.

[0369] The aerosol generating substrate rod 112 contains shredded tobacco material. The aerosol generating substrate rod 112 contains 150 milligrams of shredded tobacco material containing 13 to 16 weight percent glycerin. The density of the aerosol generating substrate is approximately 300 mg per cubic centimeter. The ready-to-drink (RTD) of the aerosol generating substrate rod 112 is approximately 6 to 8 mmH2O. The aerosol generating substrate rod 112 is individually packaged with a plug wrap (not shown).

[0370] The hollow tubular element 122 is located immediately downstream of the rod 112 of the aerosol generating substrate, and is aligned with the rod 112 in the longitudinal direction. The upstream end of the hollow tubular element 122 abuts against the downstream end of the rod 112 of the aerosol generating substrate.

[0371] The hollow tubular element 122 defines the hollow section of the aerosol-generating article 110. The hollow tubular element 122 does not substantially contribute to the overall RTD of the aerosol-generating article. More specifically, the RTD of the hollow tubular element 122 is approximately 0 mmH2O.

[0372] As shown in Figure 3, the hollow tubular element 122 is provided in the form of a hollow cylindrical tube made of cardboard. The hollow tubular element 122 defines an internal cavity that extends all the way from the upstream end to the downstream end of the hollow tubular element 122. The internal cavity is substantially empty, and thus allows for substantially unrestricted airflow along the internal cavity.

[0373] The hollow tubular element 122 has a length of approximately 21 millimeters, an outer diameter of approximately 7.2 millimeters, and an inner diameter of approximately 6.7 millimeters. Therefore, the thickness of the peripheral wall of the hollow tubular element 122 is approximately 0.25 millimeters.

[0374] The aerosol-generating article 100 includes a ventilation zone 160 located along a hollow tubular element 122. The ventilation zone 160 comprises a circumferential row of openings or perforations surrounding the hollow tubular element 122. The perforations of the ventilation zone 160 extend through the walls of the hollow tubular element 122 to allow fluid to flow from the outside of the article 100 into the internal cavity. The ventilation level of the aerosol-generating article 100 is approximately 16 percent.

[0375] The aerosol generating article 100 has an upstream section 140 located upstream of the rod 112, at the top of the downstream section 14 located downstream of the rod 112 of the aerosol generating substrate. Thus, the aerosol generating article 10 extends from a distal end 116 substantially coinciding with the upstream end of the upstream section 140 to a mouth end or downstream end 118 substantially coinciding with the downstream end of the downstream section 114.

[0376] As briefly described above, the upstream section 116 comprises an upstream plug element 124 located immediately upstream of the rod 112 of the aerosol generating substrate, and the upstream plug element 124 is aligned with the rod 112 in the longitudinal direction. The downstream end of the upstream plug element 124 abuts against the upstream end of the rod 112 of the aerosol generating substrate. The upstream plug element 124 has a wall thickness of about 1 mm and is provided in the form of a hollow cylindrical plug with a filtration material that defines an upstream internal cavity. The upstream element 124 has a length of about 5 mm. The outer diameter of the upstream plug element 124 is about 7.1 mm. The inner diameter of the upstream plug element 42 is about 5.1 mm.

[0377] The mouthpiece element 150 extends from the downstream end of the hollow tubular element 122 to the downstream end or oral end of the aerosol generating article 100. The mouthpiece element 150 has a length of approximately 7 mm. The outer diameter of the mouthpiece element 150 is approximately 7.2 mm.

[0378] The mouthpiece element 150 is provided in the form of a cylindrical plug element comprising a paper material and an additive coating applied to the paper material, the additive coating comprising at least one exogenous polysaccharide and an additive for reducing phenol. The total content of exogenous polysaccharides in the plug element is at least 5 weight percent of the plug element.

[0379] In the aerosol generating article 100 shown in Figure 3, the plug element 124 of the upstream section 116 may be made of the same material according to the present invention used in the mouthpiece element 150.

[0380] Examples of suitable formulations for additive coating solutions and processes for manufacturing plug elements according to the present invention are described below.

[0381] Preparation A A sheet of paper having a density of less than 0.7 grams / cubic centimeter is impregnated with an aqueous solution of processed potato starch, and an aqueous solution of triethyl citrate (TEC) is applied by spraying onto the impregnated paper sheet. Plug elements are thus formed from the treated paper sheet. The impregnation and spraying processes are carried out such that the potato starch content in the impregnated paper sheet is 5 weight percent of the paper material on a dry weight basis, and the TEC content in the plug elements is 3 weight percent of the paper material on a dry weight basis.

[0382] Preparation B A sheet of kraft paper with a basis weight of 50 gsm is impregnated with an aqueous solution containing 10 wt percent processed potato starch (e.g., Avebe X115 from Roy Avebe), 6 wt percent triethyl citrate (TEC), and 1 wt percent lecithin.

[0383] After impregnation with the aqueous solution, the basis weight of the treated paper increases to 53 gsm to 54 gsm.

[0384] Preparation C A single sheet of tissue paper with a basis weight of 40 gsm is impregnated with an aqueous solution containing 12 wt percent acetylated starch oxide (Perfectamyl A4692 AC, manufactured by Avebe) and 6 wt percent polyethylene glycol 400 (PEG400). PEG400 is a low molecular weight grade polyethylene glycol with good hydrophilicity.

[0385] After impregnation with the aqueous solution, the basis weight of the treated paper increases from 40 gsm to approximately 46 gsm.

[0386] Preparation D A single sheet of tissue paper having a basis weight of 40 gsm is impregnated with an aqueous solution containing 12 wt percent acetylated oxidized starch (Perfectamyl A4692 AC, manufactured by Avebe) and 6 wt percent ethoxyhydrogenated castor oil (Sympathens TRH / 400, manufactured by KLK Oleo).

[0387] After impregnation with the aqueous solution, the basis weight of the treated paper increases from 40 gsm to approximately 46 gsm.

[0388] Preparation E A single sheet of tissue paper having a basis weight of 40 gsm is impregnated with an aqueous solution containing 12 wt percent acetylated oxidized starch (Perfectamyl A4692 AC, manufactured by Avebe) and 6 wt percent polysorbate 20 (Tween 20, manufactured by Sigma Aldrich).

[0389] After impregnation with the aqueous solution, the basis weight of the treated paper increases from 40 gsm to approximately 46 gsm.

[0390] Preparation F (comparison) A single sheet of tissue paper with a basis weight of 40 gsm is impregnated with an aqueous solution containing 18 weight percent acetylated oxidized starch (Perfectamyl A4692 AC, manufactured by Avebe).

[0391] After impregnation with the aqueous solution, the basis weight of the treated paper increases from 40 gsm to approximately 46 gsm.

[0392] Evaluation of the impact on taste The aerosol generating article is prepared to include a rod of shredded cigarette and a mouthpiece filter segment.

[0393] A set of identical aerosol-generating articles according to the present invention (IA) is prepared, each aerosol-generating article being prepared by attaching a rod of tobacco, shredded by a strip of chipping paper, to a mouthpiece filter formed from a plug of processed paper material prepared according to preparation A above.

[0394] A set of identical comparative articles (CAs) is prepared, each comparative article being prepared by attaching a rod of tobacco, shredded by a strip of chipping paper, to a mouthpiece filter formed of a cellulose acetate tow plug having a length of 10 mm and a mouth-end hollow tubular element having a length of 11 mm. This arrangement ensures that the mouthpiece filters of the aerosol-generating articles and the comparative articles according to the present invention have substantially the same filtration efficiency.

[0395] The test panels are assembled. Each test panel component is required to smoke both the comparative article and the aerosol-generating article according to the present invention, and to score each of them with respect to general sensory stimulation characteristics such as impact, reaction (mouth and throat), sweetness, spiciness, bitterness, dryness, cleanliness, tobacco strength, flavor strength, and astringency.

[0396] Evaluations conducted by the test panel indicated that the aerosol produced by induced article IA was generally perceived by the test panel members as being quite similar to the aerosol produced by article CA. In particular, the test panel members assigned very similar scores to both articles in terms of overall reaction, sweetness, spiciness, and flavor intensity.

[0397] Phenol scavenging performance In accordance with the above description, tests were conducted to evaluate the capabilities of the plug element for use in the downstream element of an aerosol generating article.

[0398] For this purpose, processed tissue papers of preparations C, D, E, and F were used to produce substantially cylindrical plugs having a length of 21 millimeters and a diameter of approximately 8 millimeters.

[0399] Plugs prepared from treated tissue papers of Preparations C, D, and E are in accordance with this disclosure, in which each plug is treated with an additive coating containing one of several different additives for reducing exogenous polysaccharides and phenols. In contrast, a plug prepared from treated tissue paper of Preparation F provides a comparative plug and is formed from tissue paper treated with an additive coating containing exogenous polysaccharides not combined with any additive for reducing phenols.

[0400] The phenol capture performance of the plugs was evaluated by measuring their o-cresol retention rate. For this purpose, a gas stream containing o-cresol at a known concentration (KC) in nitrogen was supplied and flowed through each individual plug, and the residual concentration (RC) of o-cresol in the gas stream downstream of the plug was determined by gas chromatography-mass spectrometry (GC-MS). The [(KC-RC) / KC] ratio was taken as the o-cresol retention rate of the plug. The data on the determined o-cresol retention rates for the plugs are provided in Table 1 below. This allows for a comparison between the phenol capture performance of plugs for use in the downstream element of an aerosol generating article according to the present invention and the phenol capture performance of plugs containing a single exogenous polysaccharide. [Table 1]

[0401] Plugs prepared from treated tissue papers of preparations C, D, and E perform significantly better than plugs prepared from treated tissue papers of preparation F. In particular, plugs prepared from treated tissue papers of preparations D and E are 525 percent and 462 percent better, respectively, than plugs prepared from treated tissue papers of preparation F.

[0402] In addition to enhanced phenol scavenging performance, the use of ethoxylated castor oil in Preparation D, or polysorbate in Preparation E, in combination with exogenous polysaccharides may offer further benefits. Because ethoxylated castor oil and polysorbate have larger molecular weights than PEG400, they have been observed to exhibit relatively low migration or seepage tendencies. This makes them particularly suitable candidates for use in downstream elements of aerosol-generating articles according to the present invention.

[0403] 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 within them, which may or may not be specifically listed herein. Thus, in this context, numerical value A is understood as A ± 5% of A. In this context, numerical value A may be considered to include numerical values ​​within the general standard error range for the measurement of the characteristic that numerical value A modifies. In some examples used in the appended claims, numerical value A may deviate by the percentages listed above, as long as the amount of deviation from A does not substantially affect the fundamental and novel characteristics of the invention described in the claims. Furthermore, all ranges include the disclosed maximum and minimum points and any intermediate ranges within them, which may or may not be specifically listed herein.

Claims

1. Aerosol-generating article, Aerosol generating substrate and A downstream element provided downstream of the aerosol generating substrate and aligned axially with the aerosol generating substrate, The downstream element is equipped with, Paper materials and, The additive coating applied to the aforementioned paper material, The plug element comprises a cellulose-based filter material comprising, and the additive coating is At least one exogenous polysaccharide, At least one additive for reducing phenol, Equipped with, The aforementioned at least one exogenous polysaccharide comprises acetylated starch or oxidized acetylated starch, The plug element contains, on a dry weight basis, at least 5 weight percent of the acetylated starch or oxidized acetylated starch based on the dry weight of the paper material. Aerosol-generating items.

2. The aerosol generating article according to claim 1, wherein the at least one exogenous polysaccharide further comprises starch, modified starch, alkenyl succinate starch, pullulan, alginate, and combinations thereof.

3. The aerosol-generating article according to claim 1 or 2, wherein the at least one additive for reducing phenol is selected from ethoxylated castor oil, polysorbate, and combinations thereof.

4. The aerosol generating article according to any one of claims 1 to 3, wherein the at least one additive for reducing phenol is selected from polycarboxylic acids, polyether polyols, and combinations thereof.

5. The aerosol generating article according to any one of claims 1 to 4, wherein the at least one additive for reducing phenol is selected from the group consisting of triethyl citrate, polyethylene glycol, and combinations thereof.

6. The aerosol generating article according to any one of claims 1 to 5, wherein the additive coating further comprises a nonionic surfactant.

7. The aerosol generating article according to any one of claims 1 to 6, wherein the plug element contains 10% by weight or less of the additive for reducing phenol on a dry weight basis.

8. The aerosol generating article according to any one of claims 1 to 7, wherein the plug element contains at least 1 weight percent of the additive for reducing phenol.

9. The aerosol generating article according to any one of claims 1 to 8, wherein the combined amount of the at least one exogenous polysaccharide in the plug element and the additive for reducing phenol is less than 20 percent by weight on a dry weight basis.

10. The aerosol generating article according to any one of claims 1 to 9, wherein the weight ratio of the at least one exogenous polysaccharide in the additive coating to the additive for reducing phenol is at least 1.2 on a dry weight basis.

11. The aerosol generating article according to any one of claims 1 to 10, wherein the cellulose-based filter material comprises at least 1 weight percent of the additive coating.

12. The aerosol generating article according to any one of claims 1 to 11, wherein the plug element substantially does not contain cellulose acetate.

13. The aerosol generating article according to any one of claims 1 to 12, wherein the downstream element is a mouthpiece filter segment comprising the plug element and a filter wrapper surrounding the plug element.

14. A method for producing a cellulose-based filter material for forming a plug element of an aerosol generating article according to claim 1, The process of providing paper materials, A step of forming an additive-coated solution containing at least one exogenous polysaccharide and an additive for reducing phenol, The steps include applying the additive coating solution to the paper material, The process includes drying the coated paper material and optionally hardening it, A step of forming a plug element including the covered paper material, Includes, The aforementioned at least one exogenous polysaccharide comprises acetylated starch or oxidized acetylated starch, The content of acetylated starch or oxidized acetylated starch in the plug element is at least 5% by weight of the plug element on a dry weight basis. method.

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