Aerosol-generating articles with downstream obstacles

Abstract

The present invention relates to an aerosol-generating article including a mouthpiece portion. The mouthpiece portion is hollow and cylindrical. The mouthpiece portion includes a sheet. The sheet is disposed as either or both of the following: within the mouthpiece portion and forming the inner side wall of the mouthpiece portion. The sheet includes projections extending at an angle from the sheet. The present invention further relates to a method for forming the mouthpiece portion of an aerosol-generating article.

Description

Technical Field

[0001] The present invention relates to aerosol-generating articles and also to a method for forming a mouthpiece portion for an aerosol-generating article.

Background Art

[0002] It is known to provide aerosol-generating articles for generating inhalable vapors. Such articles may comprise an aerosol-forming substrate that is heated to a temperature at which one or more components of the aerosol-forming substrate volatilize without combustion of the aerosol-forming substrate. The aerosol-forming substrate may be provided as part of the substrate portion of the aerosol-generating article. The aerosol-generating article may have a rod shape for insertion into a cavity of an aerosol-generating device, for example into a heating chamber. Since a relatively low temperature is used to vaporize the aerosol-forming substrate, it may not be necessary to provide a filter downstream of the substrate portion. However, having a hollow portion downstream of the substrate portion can be unpleasant for the user. Furthermore, it can be unpleasant for the user if the aerosol-forming substrate loosens and falls out of the downstream open end of the aerosol-forming article.

Summary of the Invention

Problems to be Solved by the Invention

[0003] It is desirable to eliminate the need for a downstream filter from the aerosol-generating article. With respect to the aerosol-generating article, it is desirable to prevent the fall of the aerosol-forming substrate from the aerosol-generating article downstream of the substrate portion of the aerosol-generating article. With respect to the aerosol-generating article, it is desirable not to obstruct the unobstructed view of the substrate portion of the aerosol-generating article.

Brief Description of the Drawings

[0004] [Figure 1] FIG. 1 shows an aerosol-generating article according to the present invention. [Figure 2]Figure 2 shows the wrapping of the aerosol-generating material with a sheet. [Figure 3] Figure 3 shows a further embodiment relating to the wrapping of a sheet around an aerosol-generating article. [Figure 4] Figure 4 shows a further embodiment relating to the wrapping of an aerosol-generating article in a sheet. [Figure 5] Figures 5A to 5E show cross-sectional views of different wrapping techniques. [Figure 6] Figures 6A to 6F show cross-sectional views of an embodiment of a sheet having protrusions. [Figure 7] Figure 7 shows one embodiment of a sheet of aerosol-generating material. [Figure 8] Figure 8 shows the winding operation of the sheet in Figure 7. [Figure 9] Figure 9 shows a cross-sectional view of an unfolded projection. [Figure 10] Figure 10 shows a side view of the unfolded projection. [Figure 11] Figures 11A and 11B show further embodiments of a sheet having protrusions. [Figure 12] Figure 12 shows the winding operation of the sheet in Figure 11. [Figure 13] Figures 13A and 13B show further embodiments of the sheet protrusions. [Figure 14] Figure 14 shows a further embodiment in which the sheet is placed inside the hollow cylindrical mouthpiece portion of the aerosol generating article. [Figure 15] Figure 15 shows a cross-sectional view of the configuration of the sheet's protrusions. [Figure 16] Figure 16 shows a side cross-sectional view of the projection in Figure 15. [Figure 17] Figures 17A and 17B show the configuration of the sheets in Figures 15 and 16 before they are folded. [Figure 18] Figure 18 shows a further configuration of the protrusion. [Figure 19] Figures 19A to 19C show further configurations of the protrusions. [Modes for carrying out the invention]

[0005] According to one embodiment of the present invention, an aerosol generating article including a mouthpiece portion may be provided. The mouthpiece portion may be hollow and cylindrical. The mouthpiece portion may include a sheet. The sheet may be disposed as either or both of the following: within the mouthpiece portion and forming the inner side wall of the mouthpiece portion. The sheet may include projections that may extend obliquely from the sheet.

[0006] According to one embodiment of the present invention, an aerosol generating article including a mouthpiece portion is provided. The mouthpiece portion is hollow and cylindrical. The mouthpiece portion includes a sheet. The sheet is disposed as either or both of the following: within the mouthpiece portion and forming the inner side wall of the mouthpiece portion. The sheet includes projections extending at an angle from the sheet.

[0007] The sheet on the mouthpiece portion of the aerosol generating article, particularly its protrusions, may prevent the aerosol-forming substrate from falling downstream of the base portion of the aerosol generating article. The sheet on the mouthpiece portion of the aerosol generating article, particularly its protrusions, may obstruct the unobstructed view of the base portion of the aerosol generating article. The sheet on the mouthpiece portion of the aerosol generating article, particularly its protrusions, may have a filtering effect. This filtering effect may be sufficient because it reduces the amount of unwanted components in the aerosol generated from the aerosol generating article, which is heated but not burned.

[0008] The mouthpiece portion may be the most proximal part of the aerosol-generating article. The mouthpiece portion may also be the most downstream part of the aerosol-generating article.

[0009] The mouthpiece portion may have cardboard side walls. The mouthpiece portion may be dimensionally stable so as to withstand a user holding it between their lips or fingers.

[0010] The sheet may be flat. The sheet may be longer in length compared to its width. The entire sheet may be disposed inside the hollow mouthpiece portion.

[0011] The aerosol generating article may further include a substrate portion upstream of the mouthpiece portion.

[0012] The substrate portion may be directly adjacent to the mouthpiece portion. The substrate portion may contain an aerosol-forming substrate.

[0013] The aerosol generating article may include tipping paper. The tipping paper may be disposed so as to at least partially surround the mouthpiece portion and the substrate portion. The tipping paper may hold the mouthpiece portion and the substrate portion together.

[0014] The sheet may be folded and disposed within the mouthpiece portion.

[0015] The sheet may be folded into an omega shape. The sheet may be folded without having sharp folding edges. In other words, the folding edges of the sheet may be rounded. Further in other words, the "folding" of the sheet may be a bend that avoids sharp folding edges.

[0016] The sheet may be folded at least twice, preferably at least three times, more preferably at least four times.

[0017] The sheet may have a length that is 2 to 6 times, preferably 3 to 5 times, more preferably 4 times the inner diameter of the mouthpiece portion.

[0018] The extension plane of the sheet may be parallel to the longitudinal axis of the aerosol generating article.

[0019] The sheet protrusions may extend at an angle from the extended plane of the sheet. The sheet protrusions may extend at an angle of 10 to 90 degrees from the extended plane of the sheet. The sheet protrusions may extend at an angle of 20 to 90 degrees from the extended plane of the sheet. The sheet protrusions may extend at an angle of 30 to 90 degrees from the extended plane of the sheet. The sheet protrusions may extend at an angle of 40 to 90 degrees from the extended plane of the sheet. The sheet protrusions may extend at an angle of 50 to 90 degrees from the extended plane of the sheet. The sheet protrusions may extend at an angle of 60 to 90 degrees from the extended plane of the sheet. The sheet protrusions may extend at an angle of 70 to 90 degrees from the extended plane of the sheet. The sheet protrusions may extend at an angle of 80 to 90 degrees from the extended plane of the sheet. The sheet protrusions may extend perpendicularly from the extended plane of the sheet. The extension plane of the sheet may be defined before the sheet is folded. Alternatively, the extension plane may be the tangential plane at the point of contact of the projection with the sheet.

[0020] The extension planes of one or more protrusions may be parallel to the longitudinal axis of the aerosol-generating article. The extension planes of all protrusions may be parallel to the longitudinal axis of the aerosol-generating article.

[0021] The sheet may have a thickness of 50 micrometers to 1000 micrometers, preferably 200 micrometers to 500 micrometers.

[0022] The sheet may be wrapped around the mouthpiece to form the innermost layer.

[0023] In this embodiment, the sheet does not have to be folded and does not have to be disposed inside the mouthpiece portion. Instead, the sheet may form the innermost layer of the mouthpiece portion. The innermost layer of the mouthpiece portion may also be shown as the side wall or inner side wall of the mouthpiece portion.

[0024] The sheet may be wrapped around the mandrel to form the innermost layer of the mouthpiece. The wrapping may be spiral.

[0025] After the sheet is wrapped around it, the mandrel may be removed, thereby forming a hollow cylindrical mouthpiece section. The wrapped sheet may be cut to the size of individual mouthpiece sections. When wrapping the sheet around the mandrel, the sheet's protrusions may be pressed against the sheet. After wrapping the sheet around the mandrel, the sheet's protrusions may be unfolded to form an angled configuration.

[0026] The projection may extend radially inward from the innermost layer of the mouthpiece portion.

[0027] The protrusion may extend radially inward, obstructing the view from the open end of the mouthpiece towards the base.

[0028] The mouthpiece portion may have an open downstream end. The open downstream end may allow aerosols to flow from the open downstream end. The hollow structure of the mouthpiece portion may allow aerosols to flow through the mouthpiece portion.

[0029] The sheet may be arranged such that it does not affect, or has only a negligible effect on, the draw resistance of the mouthpiece portion. Due to the hollow nature of the mouthpiece portion and due to the arrangement of the sheet, the mouthpiece portion may have no draw resistance, or only a negligible draw resistance.

[0030] The sheet may be fluid-impermeable. As a result, the innermost layer of the mouthpiece portion may be fluid-impermeable. In other words, the sheet may prevent lateral airflow into the mouthpiece portion. In an alternative embodiment, the sheet may be fluid-permeable. In this embodiment, the mouthpiece portion may be fluid-permeable to lateral airflow. This may allow lateral airflow into the mouthpiece portion. Lateral airflow into the mouthpiece portion may allow ambient air to be drawn into the mouthpiece portion when the user inhales over the aerosol-generating article. This may facilitate mixing of the ambient air with air that has been drawn axially through the aerosol-generating article and contains volatile aerosol-forming substrate. This mixing may cool the air containing the volatile aerosol-forming substrate, and may also allow for the formation of aerosols due to the condensation of the volatile aerosol-forming substrate.

[0031] Axial gaps may be provided between the individual protrusions to allow airflow to pass through them.

[0032] The protrusion does not have to contribute to the resistance of drawing out the mouthpiece, or it may contribute only to a negligible degree.

[0033] The protrusions may be arranged to prevent or reduce unwanted residue or aerosol-forming substrate from falling through the gaps between the protrusions.

[0034] The distance between the protrusions may be smaller than the average particle size of the aerosol-forming substrate particles.

[0035] The sheet may include cardboard. The sheet may be made from cardboard.

[0036] The sheet may be wrapped spirally to form the innermost layer of the mouthpiece.

[0037] The sheets may overlap and be wound spirally to form the innermost layer of the mouthpiece portion.

[0038] The overlapping portions of the sheet when it is wrapped may be covered with adhesive.

[0039] The overlapping portions of the sheet when wrapped may be the attachment portions of the sheet. The attachment portions may be covered with adhesive.

[0040] The sheet may include at least a first sheet and an overlapping second sheet. One or both of the first and second sheets may include protrusions.

[0041] The sheet may include at least a third sheet and a fourth sheet. One or more of the first sheet, second sheet, third sheet, and fourth sheet may overlap. One or more of the first sheet, second sheet, third sheet, and fourth sheet may include protrusions.

[0042] The protrusions may have an extension direction perpendicular to the longitudinal axis of the aerosol-generating article.

[0043] The projection may have a triangular, rectangular, disc-shaped, teardrop-shaped, or brush-bristle shape. The projection may be a flap. The projection may be brush bristles. The projection may be one or both of the hook and loop similar to or identical to a Velcro fastener.

[0044] The protrusions may be formed integrally with the sheet.

[0045] Alternatively, the projections may be attached to the sheet. The projections may be attached to the sheet with an elastic adhesive. This may facilitate the folding of the projections that come into contact with the sheet when the sheet is wrapped around the mandrel. This may also facilitate the unfolding of the projections from the sheet after the sheet has been wrapped around the mandrel.

[0046] The sheet and / or the projection may comprise one or more fibers, threads, and yarns, preferably one or more of these.

[0047] The sheet and / or the protrusions may include, preferably be made from, cellulose, wood-derived cellulose pulp, cotton, rice, lignocellulose materials, paper, wool, silk, hemp, raffia, coconut, bamboo, or jute.

[0048] The sheet may be biodegradable. The protrusions may also be biodegradable.

[0049] The protrusions may be formed along the long edge of the sheet. The protrusions may extend from the long edge of the sheet.

[0050] The adhesive layer may be applied to the portion of the sheet opposite to the long edge where the protrusion is formed.

[0051] The protrusions may include coverings.

[0052] The coating may be configured to capture either or both phenol and flugas, or the coating may contain flavoring agents.

[0053] The present invention further relates to a method for forming a mouthpiece portion of an aerosol generating article, wherein this method

[0054] A process for providing a sheet including protrusions,

[0055] The process involves wrapping a sheet around the mandrel to form the innermost layer of the hollow cylindrical mouthpiece portion, or arranging a sheet inside the mouthpiece portion.

[0056] The process may also include extending the protrusions diagonally relative to the sheet.

[0057] This method may include bringing the protrusions into contact with the sheet and folding it before wrapping the sheet around it.

[0058] The projection may be configured to automatically unfold after the wrapped sheet is removed from the mandrel.

[0059] The present invention may further relate to an aerosol generator configured for use with an aerosol generating article described herein.

[0060] The present invention may further relate to an aerosol generating system comprising an aerosol generating device and an aerosol generating article as described herein.

[0061] The aerosol generator may include a cavity for receiving the aerosol generating article.

[0062] The aerosol generator may be equipped with a heating element for heating the aerosol-forming substrate.

[0063] The aerosol generator may be equipped with a controller for controlling the operation of the heat-generating element.

[0064] The aerosol generator may be equipped with a power supply for providing power to the heating element and the controller.

[0065] As used herein, the terms “proximal,” “distal,” “downstream,” and “upstream” are used to describe the relative position of a component of an aerosol generator, or a part of such component, with respect to the direction in which the user draws the aerosol generator or aerosol generating article during its use.

[0066] An aerosol generator may include a mouth end through which aerosols are delivered to the user during use. The mouth end may also be called the proximal end. During use, the user inhales the proximal end, i.e., the mouth end, of the aerosol generator to inhale the aerosols generated by the aerosol generator. Alternatively, the user may directly inhale an aerosol-generating article inserted into an opening at the proximal end of the aerosol generator. The opening at the proximal end may be a cavity opening. The cavity may be configured to receive an aerosol-generating article. The aerosol generator has a distal end located opposite the proximal end, i.e., the mouth end. The proximal end, i.e., of the aerosol generator may also be called the downstream end, and the distal end of the aerosol generator may also be called the upstream end. Each component of an aerosol generator, or each part of each component, may be described as being upstream or downstream of each other based on their relative positions between the proximal end, i.e., downstream end, i.e., mouth end, and the distal end, i.e., upstream end, of the aerosol generator.

[0067] As used herein, “aerosol generator” refers to a device that generates an aerosol by interacting with an aerosol-forming substrate. The aerosol-forming substrate may be part of an aerosol-generating article, for example, part of a smoking article. The aerosol generator may be a smoking device that interacts with the aerosol-forming substrate of an aerosol-generating article to generate an aerosol that can be directly inhaled into the user's lungs through the user's mouth. The aerosol generator may be a holder. The device may be an electrically heated smoking device. The aerosol generator may comprise a housing, an electrical circuit, a power supply, a heating chamber, and a heating element.

[0068] As used herein in relation to the present invention, the term “smoking” in relation to apparatus, articles, systems, substrates, or otherwise does not refer to conventional smoking in which the aerosol-forming substrate is completely or at least partially burned. The aerosol-generating apparatus of the present invention is configured to heat the aerosol-forming substrate to a temperature below the combustion temperature of the aerosol-forming substrate, but above the temperature at which one or more volatile compounds of the aerosol-forming substrate are released, in order to form an inhalable aerosol.

[0069] The aerosol generator may include an electrical circuit. The electrical circuit may include a microprocessor, which may be a programmable microprocessor. The microprocessor may be part of a controller. The electrical circuit may include further electronic components. The electrical circuit may be configured to regulate the power supply to a heating element. Power may be supplied to the heating element continuously following the startup of the aerosol generator, or intermittently, such as with each smoke extraction. Power may be supplied to the heating element in the form of current pulses. The electrical circuit may be configured to monitor the electrical resistance of the heating element, and preferably to control the power supply to the heating element in accordance with its electrical resistance.

[0070] An aerosol generator may have a power source, typically a battery, inside the main body of the aerosol generator. In one embodiment, the power source is a lithium-ion battery. Alternatively, the power source may be a nickel-metal hydride battery, a nickel-cadmium battery, or a lithium-based battery such as a lithium-cobalt battery, lithium iron phosphate, lithium titanate, or lithium polymer battery. Alternatively, the power source may be another form of charge storage device, such as a capacitor. The power source may require recharging and may have a capacity that allows for the storage of sufficient energy for one or more use experiences. For example, the power source may have a capacity sufficient to continuously generate aerosols for a period of about six minutes, or for a period of a multiple of six minutes. In another example, the power source may have a capacity sufficient to provide a predetermined number of fume inhalations or to provide discontinuous activation of a heating element.

[0071] The cavity of the aerosol generator may have an open end into which an aerosol generating article is inserted. The open end may be the proximal end. The cavity may have a closed end located opposite the open end. The closed end may be the base of the cavity. The closed end may be closed except for the installation of an air opening disposed within the base. The base of the cavity may be flat. The base of the cavity may be circular. The base of the cavity may be located upstream of the cavity. The open end may be located downstream of the cavity. The cavity may have an elongated extension. The cavity may have a central axis in the longitudinal direction. The longitudinal direction may be a direction that extends along the central axis in the longitudinal direction between the open end and the closed end. The central axis in the longitudinal direction of the cavity may be parallel to the longitudinal axis of the aerosol generator.

[0072] The cavity may be configured as a heating chamber. The cavity may have a cylindrical shape. The cavity may have a hollow cylindrical shape. The cavity may have a shape corresponding to the shape of the aerosol-generating article received inside the cavity. The cavity may have a circular cross-section. The cavity may have an elliptical or rectangular cross-section. The cavity may have an inner diameter corresponding to the outer diameter of the aerosol-generating article.

[0073] The airflow channel may extend through the cavity. Ambient air may be drawn further into the cavity into the aerosol generator, or it may be drawn towards the user through the airflow channel. A mouthpiece may be located downstream of the cavity, or the user may directly inhale the aerosol generating object. The airflow channel may extend through the mouthpiece.

[0074] In any aspect of this disclosure, the heating element may include an electrical resistive material. Suitable electrical resistive materials include, but are not limited to, semiconductors such as doped ceramics, "conductive" ceramics (e.g., molybdenum disilide), carbon, graphite, metals, alloys, and composite materials made of ceramic and metallic materials. Such composite materials may include doped ceramics or undoped ceramics. An example of a suitable doped ceramic is doped silicon carbide. Examples of suitable metals include titanium, zirconium, tantalum platinum, gold, and silver. Examples of suitable metallic alloys include stainless steel, nickel-containing, cobalt-containing, chromium-containing, aluminum-containing, titanium-containing, zirconium-containing, hafnium-containing, niobium-containing, molybdenum-containing, tantalum-containing, tungsten-containing, tin-containing, gallium-containing, manganese-containing, gold-containing, and iron-containing alloys, as well as nickel, iron, cobalt, stainless steel-based superalloys, Timetal®, and iron-manganese-aluminum alloys. In composite materials, the electrical resistive material may be embedded in, sealed in, or coated with an insulating material, depending on the required energy transfer dynamics and external physicochemical properties, or vice versa.

[0075] As described, in any aspect of this disclosure, the heating element may be part of an aerosol generator. The aerosol generator may comprise an internal heating element, an external heating element, or both internal and external heating elements, where “internal” and “external” refer to the aerosol-forming substrate. The internal heating element may take any suitable form. For example, the internal heating element may take the form of a heating blade. Alternatively, the internal heater may take the form of a casing or substrate having different conductive parts or electrically resistive metal tubes. Alternatively, the internal heating element may be one or more heating needles or rods passing through the center of the aerosol-forming substrate. Other alternatives include heating wires or filaments, such as Ni-Cr (nickel-chromium), platinum, tungsten, or alloy wires or heating plates. Optionally, the internal heating element may be located inside or on a rigid carrier material. In such one embodiment, the electrically resistive heating element may be formed using a metal having a clear relationship between temperature and resistivity. In such exemplary devices, the metal may be formed as a track on a suitable insulating material such as a ceramic material and then sandwiched between other insulating materials such as glass. The heater thus formed may be used in operation for both the purpose of heating the heating element and for the purpose of monitoring the temperature of the heating element.

[0076] The external heating element may take any preferred form. For example, the external heating element may take the form of one or more flexible heating foils on a dielectric substrate such as polyimide. The flexible heating foils can be shaped to fit the periphery of the substrate receiving cavity. Alternatively, the external heating element may take the form of a metal grid, a flexible printed circuit board, a molded interconnect (MID), a ceramic heater, a flexible carbon fiber heater, or may be formed on a substrate of a preferred shape using a coating technique such as plasma deposition. The external heating element may also be formed using a metal having a clear relationship between temperature and resistivity. In such an exemplary device, the metal may be formed as a track located between two layers of a suitable insulating material. The external heating element thus formed may be used during operation for both the purpose of heating the external heating element and for the purpose of monitoring the temperature of the external heating element.

[0077] As an alternative to electrically resistive heating elements, heating elements may be configured as inductive heating elements. Inductive heating elements may comprise an induction coil and a susceptor. Generally, a susceptor is a material that can generate heat when penetrated by an alternating magnetic field when located within an alternating magnetic field. If the susceptor is conductive, typically eddy currents are induced by the alternating magnetic field. If the susceptor is magnetic, typically another effect contributing to heating is generally called hysteresis loss. Hysteresis loss arises primarily from the movement of magnetic domain blocks within the susceptor, as these magnetic orientations align with the alternating induced magnetic field. Another effect contributing to hysteresis loss is when magnetic domains expand or contract within the susceptor. Generally, all these changes occurring at sub-nanometer scales within the susceptor are called "hysteresis loss" because they generate heat within the susceptor. Therefore, if the susceptor is both magnetic and conductive, both hysteresis loss and eddy current generation contribute to the heating of the susceptor. If the susceptor is magnetic but not conductive, hysteresis loss becomes the only means by which the susceptor is heated when penetrated by an alternating magnetic field. According to the present invention, the susceptor may be conductive, magnetic, or both conductive and magnetic. An alternating magnetic field generated by one or more induction coils heats the susceptor, which then transfers heat to the aerosol-forming substrate, thereby forming an aerosol. Heat transfer may be mainly by conduction. Such heat transfer is best when the susceptor is in close thermal contact with the aerosol-forming substrate.

[0078] As used herein, the term “aerosol-generating article” refers to an article comprising an aerosol-forming substrate capable of releasing volatile compounds that can form aerosols. The aerosol-forming substrate may be part of a substrate. For example, an aerosol-generating article may be a smoking article that generates an aerosol that can be directly inhaled into the user's lungs through the user's mouth. An aerosol-generating article may be disposable.

[0079] The aerosol-generating article may include at least a base portion and a mouthpiece portion, as described herein.

[0080] As used herein, the term “aerosol-forming substrate” refers to a substrate capable of releasing one or more volatile compounds that can form aerosols. These volatile compounds may be released by heating the aerosol-forming substrate. Conveniently, the aerosol-forming substrate may be part of an aerosol-generating article or a smoking article.

[0081] The aerosol-forming substrate may be a solid aerosol-forming substrate. The aerosol-forming substrate may contain both solid and liquid components. The aerosol-forming substrate may contain a tobacco-containing material that contains volatile tobacco-flavored compounds released from the substrate upon heating. The aerosol-forming substrate may contain non-tobacco materials. The aerosol-forming substrate may contain an aerosol-forming agent that facilitates the formation of a high-density and stable aerosol. Examples of suitable aerosol-forming agents are glycerin and propylene glycol.

[0082] The aerosol generating substrate preferably comprises homogenized tobacco material, an aerosol forming body, and water. Providing homogenized tobacco material may improve aerosol generation and the nicotine content and flavor profile of the aerosol generated during heating of the aerosol generating article. Specifically, the process of producing homogenized tobacco involves a process of crushing tobacco leaves, which allows for more effective release of nicotine and flavor during heating. [Examples]

[0083] A non-exclusive list of non-limiting embodiments is provided below. Any one or more features in these embodiments may be combined with any one or more features in other embodiments, other forms, or other aspects described herein.

[0084] Example 1. An aerosol generating article comprising a mouthpiece portion, wherein the mouthpiece portion is hollow and cylindrical, and the mouthpiece portion includes a sheet, the sheet being disposed as either or both being inside the mouthpiece portion and forming the inner side wall of the mouthpiece portion, and the sheet includes projections extending diagonally from the sheet. Example 2. The aerosol generating article according to Example 1, wherein the aerosol generating article further includes a base portion upstream of the mouthpiece portion. Example 3. An aerosol generating article according to Example 1 or 2, wherein the sheet is folded and placed inside the mouthpiece portion. Example 4. The aerosol-generating article according to Example 3, wherein the sheet is folded at least twice, preferably at least three times, and more preferably at least four times. Example 5. An aerosol generating article according to any one of Examples 1 to 4, wherein the sheet has a length of 2 to 6 times the inner diameter of the mouthpiece portion, preferably 3 to 5 times the inner diameter of the mouthpiece portion, and more preferably 4 times the inner diameter of the mouthpiece portion. Example 6. An aerosol generating article according to any one of Examples 1 to 5, wherein the extended plane of the sheet is parallel to the longitudinal axis of the aerosol generating article. Example 7. An aerosol generating article according to any one of Examples 1 to 6, wherein the sheet has a thickness of 50 micrometers to 1000 micrometers, preferably 200 micrometers to 500 micrometers. Example 8. An aerosol generating article according to any one of Examples 1 to 7, wherein the sheet is wrapped around to form the innermost layer of the mouthpiece portion. Example 9. The aerosol generating article according to Example 8, wherein the projection extends radially inward from the innermost layer of the mouthpiece portion. Example 10. An aerosol generating article according to any of Examples 2 to 9, wherein the projection extends radially inward from the open end of the mouthpiece portion so as to obstruct the view of the base portion. Example 11. An aerosol generating article according to any one of Examples 1 to 10, wherein the mouthpiece portion has an open downstream end. Example 12. An aerosol generating article according to any one of Examples 1 to 11, wherein axial gaps are provided between the individual protrusions, allowing airflow through the protrusions. Example 13. An aerosol generating article according to any one of Examples 1 to 12, wherein the protrusions are arranged to prevent or reduce unwanted residue or aerosol-forming substrate from the base portion in Example 2 from falling through the individual protrusions. Example 14. An aerosol-generating article according to any one of Examples 1 to 13, wherein the sheet includes cardboard, and preferably the sheet is made from cardboard. Example 15. An aerosol generating article according to any one of Examples 1 to 14, wherein the sheet is spirally wound to form the innermost layer of the mouthpiece portion. Example 16. The aerosol generating article according to Example 15, wherein the sheets are overlapped and wound spirally to form the innermost layer of the mouthpiece portion. Example 17. The aerosol-generating article according to Example 16, wherein the overlapping sheet portions when rolled are covered with an adhesive. Example 18. An aerosol generating article according to any of Examples 1 to 17, wherein the sheet comprises at least a first sheet and an overlapping second sheet, and one or both of the first and second sheets include protrusions. Example 19. The aerosol generating article according to Example 18, wherein the sheet includes at least a third sheet and a fourth sheet, and one or more of the first sheet, second sheet, third sheet, and fourth sheet are overlapping. Example 20. An aerosol generating article according to any one of Examples 1 to 19, wherein the protrusion has an extension direction perpendicular to the longitudinal axis of the aerosol generating article. Example 21. An aerosol generating article according to any one of Examples 1 to 20, wherein the protrusions are triangular, rectangular, disc-shaped, teardrop-shaped, or brush-bristle-shaped. Example 22. An aerosol generating article according to any one of Examples 1 to 21, wherein the protrusions are formed integrally with the sheet. Example 23. An aerosol-generating article according to any one of Examples 1 to 21, wherein the protrusions are attached to a sheet, preferably with an elastic adhesive. Example 24. An aerosol-generating article according to any of Examples 1 to 23, wherein one or both of the sheet and the protrusions include, preferably, one or more of, fibers, threads, and yarns. Example 25. An aerosol-generating article according to any one of Examples 1 to 24, wherein one or both of the sheet and / or protrusions contain, and preferably consist of, cellulose, wood-derived cellulose pulp, cotton, rice, lignocellulose material, paper, wool, silk, hemp, raffia, coconut, bamboo, or jute. Example 26. An aerosol generating article according to any one of Examples 1 to 25, wherein the protrusions are formed along the long edge of the sheet. Example 27. The aerosol-generating article according to Example 26, wherein the adhesive layer in Example 17 is applied to the portion of the sheet opposite to the long edge where the protrusions are formed. Example 28. An aerosol generating article according to any of Examples 1 to 27, wherein the protrusions include a coating. Example 29. The aerosol-generating article according to Example 28, wherein the coating is configured to capture one or both of phenol and flugas, or the coating contains a flavoring agent. Example 30. A method for forming the mouthpiece portion of an aerosol generating article, - A process of providing a sheet including protrusions, - A process of wrapping a sheet around the mandrel to form the innermost layer of the hollow cylindrical mouthpiece portion, or placing a sheet inside the mouthpiece portion, A method comprising the step of extending a protrusion diagonally with respect to a sheet. Example 31. The method according to Example 30, wherein the method includes folding the protrusions relative to the sheet before wrapping the sheet around it. Example 32. The method according to Example 31, wherein the projection is configured to automatically unfold after the wrapped sheet is removed from the mandrel.

[0085] Each feature described in relation to one embodiment may be equally applicable to other embodiments of the present invention.

[0086] The present invention will be further described with reference to the accompanying drawings for illustrative purposes only.

[0087] Figure 1 shows an aerosol generating article 10. The aerosol generating article 10 includes a mouthpiece portion 12. The mouthpiece portion 12 is hollow and cylindrical. Figure 1 further shows a base portion 14 of the aerosol generating article 10. The base portion 14 includes an aerosol-forming substrate.

[0088] Figure 1 further illustrates a further portion of the aerosol generating article 10. The further portion is preferably a cooling portion 16. The cooling portion 16 may include perforations (not shown) to allow ambient air to be drawn into the aerosol generating article 10 and mixed with the air drawn through the aerosol generating article 10. The perforations may be provided in the sidewalls of the cooling portion 16. The mixing of ambient air with the air drawn through the aerosol generating article 10 may enable the formation of an aerosol within the cooling portion 16 due to the condensation of a vaporized aerosol-forming substrate, i.e., the formation of droplets consisting of the vaporized aerosol-forming substrate. The aerosol is then drawn into the user's mouth through the mouthpiece portion 12.

[0089] Figure 1 further shows a front plug 18. The front plug 18 may include a filter element, such as an acetate tow filter element. The front plug 18 may prevent the aerosol-forming substrate from falling from the upstream end 20 of the aerosol-generating article 10. Preferably, the front plug 18 is located at the most upstream part of the aerosol-generating article 10. In other words, the front plug 18 is located at the upstream end 20 of the aerosol-generating article 10. This may also be referred to as the distal end or distal portion of the aerosol-generating article 10.

[0090] A base portion 14 is disposed downstream or proximal to the forward plug 18. As mentioned above, the base portion 14 contains an aerosol-forming substrate. The base portion 14 may also be represented as a sensory medium portion, and the aerosol-forming substrate may also be represented as a sensory medium. The aerosol-forming substrate is configured to be vaporized by the heating action of the aerosol generator. The aerosol generator, although not shown in Figure 1, may include a cavity for receiving an aerosol-generating article 10 and a heating element at least partially disposed around the cavity to heat the base portion 14 of the aerosol-generating article 10.

[0091] A cooling portion 16 of the aerosol generating article 10 is disposed downstream or proximal to the base portion 14. A mouthpiece portion 12 is disposed downstream or proximal to the cooling portion 16. Therefore, the mouthpiece portion 12 may be the furthest downstream or furthest proximal portion of the aerosol generating article 10. In other words, the mouthpiece portion 12 may be disposed at the downstream end 22 or the proximal end of the aerosol generating article 10.

[0092] During use, the user may inhale air through the aerosol generating article 10 by directly contacting the mouthpiece portion 12 with their lips. As mentioned above, ambient air may also be drawn into the aerosol generating article 10 through the perforations in the cooling portion 16.

[0093] Figure 2 shows a sheet 24 of the aerosol generating article 10. Figures 2 to 13 show a first major embodiment of the present disclosure, in which the sheet 24 forms the innermost side wall of the hollow cylindrical mouthpiece portion 12 of the aerosol generating article 10. Figures 14 to 19 show a second major embodiment of the present disclosure, in which the sheet 24 is disposed inside the hollow cylindrical mouthpiece portion 12. However, it should be noted that these embodiments can be combined. Exemplarily, the innermost layer of the mouthpiece portion 12 may be formed by the sheet 24 according to any of Figures 2 to 13, and additionally or alternatively, the sheet 24 may be disposed inside the inner hollow mouthpiece portion 12 as shown in any of Figures 14 to 19.

[0094] Figure 2 shows the manufacturing process for the mouthpiece portion 12 of the aerosol generating article 10. In this manufacturing process, the sheet 24 is wrapped around the mandrel 26. The wrapping of the sheet 24 around the mandrel 26 forms a hollow cylindrical tube. In the embodiment shown in Figure 2, the individual layers of the sheet 24 are wrapped around the mandrel 26 so that they are adjacent to each other. In other words, the sheets 24 do not overlap.

[0095] The hollow cylindrical tube may then be removed from the mandrel 26 to form a hollow cylindrical mouthpiece portion 12. The hollow cylindrical tube may be cut radially to form individual mouthpiece portions 12s for individual aerosol generating articles 10.

[0096] Figure 3 shows different options for wrapping the sheet 24 around the mandrel 26. In this modification, the sheet 24 is wrapped overlappingly around the mandrel 26. Figure 3 shows the overlapping regions of the sheet 24. The overlapping regions may be covered with adhesive 28 to facilitate secure attachment between each overlapping region of the sheet 24.

[0097] Figure 4 shows yet another option for forming the innermost layer of the mouthpiece portion 12 by wrapping a sheet 24 around the mandrel 26. In the embodiment shown in Figure 4, multiple sheets 24 are used during wrapping instead of a single sheet 24 as shown in Figures 2 and 3. In the particular embodiment shown in Figure 4, four individual sheets 24 are wrapped around the mandrel 26. The sheets 24 overlap each other. More specifically, the first sheet 32 ​​overlaps the second sheet 34, the second sheet 34 overlaps the third sheet 36, and the third sheet 36 overlaps the fourth sheet 38. Note that the specific number of four sheets 24 is merely illustrative. If desired, two, three, four, or five or more sheets 24 can be used to form the innermost layer of the mouthpiece portion 12. Additionally, it will be understood that these sheets 24 may be arranged to overlap, with one or more sheets 24 overlapping each other. Alternatively, they can be arranged adjacent to each other, similar to the arrangement of a single sheet 24 in Figure 2.

[0098] Figures 5A to 5E show different winding configurations for one sheet 24 or multiple sheets 24. All of these figures show cross-sectional views of one sheet 24 or multiple sheets 24 after the winding operation. Figure 5A shows a single sheet 24 winding configuration similar to the winding operation shown in Figure 2. In this embodiment, the sheet 24 is wound such that the individual layers of the sheet 24 are adjacent to each other but do not overlap. Figure 5B shows a winding configuration in which at least two sheets 24, preferably four sheets 24, are wound in an overlapping manner as shown in Figure 4. Figure 5C shows sheets 24 wound in an overlapping manner. This can be done with a single sheet 24, as shown in Figure 3. Alternatively, two sheets 24 can be used in an overlapping manner. Figure 5D also shows overlapping between sheets 24. This overlap is assumed to form a linear inner surface. In other words, the inner surface is parallel to the long axis of the aerosol generating article 10. In other words, the sheets 24 may overlap to form a tile-like structure. Similarly, the formed outer surface is also linear and parallel to the longitudinal axis of the aerosol-generating article 10. This may be facilitated by applying pressure to the sheet 24 being wound, as shown in Figure 5C. The pressure may be created by the tension of the sheet 24 during the winding operation. Alternatively or additionally, the sheet 24 may be made of an elastic or deformable material so that the sheet 24 in the overlapping region conforms to the shape of the mandrel 26, as shown in Figure 5D. Furthermore, Figure 5E shows a winding configuration of the sheet 24 preferably consisting of four layers. The two innermost layers overlap, similar to the overlapping operation shown in Figure 5D. The two outermost layers overlap, similar to the overlap shown in Figure 5B. Note that in the embodiments shown in Figures 5A, 5C, and 5D, the sheet 24 can be realized by a single sheet 24 or by multiple sheets 24. The embodiments shown in Figures 5B and 5E are preferably facilitated by at least two sheets 24.

[0099] Figure 6 shows different configurations of the projection 40 on the sheet 24. Figure 6A shows the projection 40 integrally formed with the sheet 24. In Figure 6A, the projection 40 is folded in contact with the sheet 24. This arrangement of the projection 40 is preferred during the manufacturing process of the sheet 24. In other words, this arrangement of the projection 40 is preferred when the sheet 24 is wrapped around the mandrel 26. After this manufacturing process, the projection 40 unfolds as shown in Figure 6B. In other words, after the sheet 24 is removed from the mandrel 26, the projection 40 unfolds. As shown in Figure 6B, the projection 40 has an angle in a direction that forms an angle with respect to the extension plane of the sheet 24. The projection 40 has an angle with respect to the longitudinal axis of the aerosol generating article 10. It is particularly preferred that the projection 40 unfolds in a direction substantially perpendicular to the longitudinal axis of the aerosol generating article 10. It is preferred that the unfolding of the projection 40 occurs automatically. It is particularly preferable that the projection 40 is made of an elastic material so that the projection 40 unfolds after the wrapped sheet 24 is removed from the mandrel 26.

[0100] Figure 6C shows a different configuration of the projection 40. In this embodiment, the projection 40 is configured as brush bristles. Unlike the configurations in Figures 6A and 6B, the projection 40 in Figures 6C and 6D is not integrally formed with the sheet 24. Instead, the brush bristles are attached to the sheet 24. This may be done, for example, by adhesive 28. In Figure 6C, the projection 40 is folded in contact with the sheet 24 to allow the sheet 24 to be wrapped around the mandrel 26. In Figure 6D, the brush bristles are unfolded, similar to the projection 40 shown in Figure 6B. This may be done automatically by the elastic properties of the adhesive 28 and / or the elastic properties of the brush bristles.

[0101] Furthermore, Figures 6E and 6F show alternative options for the projection 40. In the embodiments shown in Figures 6E and 6F, the projection 40 is not integrally formed with the sheet 24. Instead, the projection 40 is attached to the sheet 24 by an elastic connection 42. The elastic connection 42 may be configured as an elastic adhesive 28. In Figure 6F, the projection 40 is folded in contact with the sheet 24 to allow the sheet 24 to be wrapped around the mandrel 26. In Figure 6E, the projection 40 is in an unfolded state before the sheet 24 is wrapped around the mandrel 26. Partial unfolding of the projection 40, similar to that in Figures 6B and 6D, is not shown in Figures 6E and 6F. After the sheet 24 has been removed from the mandrel 26, the projection 40 in Figures 6E and 6F may be unfolded in an orientation that is at an angle to the extended plane of the sheet 24. The projection 40 in Figures 6E and 6F may be made from fibers or yarn. This material is biodegradable. In all embodiments described herein, the sheet 24 itself may be made from cardboard.

[0102] Figure 7 shows the configuration of a sheet 24 having triangular projections 40. This type of projection 40 may also be exemplary called a flap. Other flap-like projections 40 are shown, for example, in Figure 19. The projections 40 in this embodiment, and potentially in all other embodiments, may be arranged adjacent to the long side of the sheet 24. The projections 40 may be arranged on the side opposite to the side to which the adhesive 28 is applied and which is used for overlapping when the sheet 24 is rolled up.

[0103] Figure 8 shows the sheet 24 from Figure 7 wrapped around the mandrel 26. The projection 40 is configured to be folded so that it is pressed against the mandrel 26 during the winding operation. After the winding operation, the projection 40 can be unfolded by removing the sheet 24 from the mandrel 26.

[0104] Figure 9 shows the projection 40 on the sheet 24 of Figures 7 and 8 in its deployed state. As shown in Figure 9, the projection 40 is deployed radially inward. As a result, the projection 40 at least partially closes off the hollow interior of the mouthpiece portion 12. This closing action may allow air to flow freely through the mouthpiece portion 12. However, it may be prevented that loose, unwanted particles from the aerosol-forming substrate of the base portion 14 of the aerosol-generating article 10 fall downstream from the mouthpiece portion 12. At the same time, an unobstructed view through the hollow inner cylindrical mouthpiece portion 12 may be obstructed by the deployed projection 40.

[0105] Figure 10 shows the same configuration as in Figure 9, but from a different viewpoint. From this viewpoint, it can be seen that her spiral winding results in the spiral arrangement of the projection 40. In this way, the projection 40 obstructs the view of the base portion 14 and prevents unwanted residue from the aerosol-forming substrate from falling from the mouthpiece portion 12, while allowing airflow to pass through the hollow interior of the mouthpiece portion 12.

[0106] Figures 11A and 11B show the unfolded projection 40, similar to the configuration in Figure 6E, while Figure 11B shows the folded projection 40, similar to the projection 40 shown in Figure 6F.

[0107] Figure 12 shows the arrangement of the protrusions 40, which are configured as brush bristles, during the operation of winding the sheet 24 around the mandrel 26. The configuration of the protrusions 40 is the same as that shown in Figures 6C and 6D. As shown in Figure 12, the brush bristles may be pressed against the sheet 24 only by the winding operation of the sheet 24 around the mandrel 26. Before and after the winding operation, the brush bristles may be in an unfolded state.

[0108] Figures 13A and 13B show further embodiments of the projection 40. In this embodiment, the projection 40 is configured as one or both of a hook and a loop, similar to the configuration of elements of a Velcro fastener. This may be particularly beneficial in filtering unwanted residue from the aerosol inhaled through the mouthpiece portion 12. In other words, this configuration of the projection 40 may provide a filtering effect with respect to the air inhaled through the mouthpiece portion 12.

[0109] Figure 14 shows a second primary embodiment of the present invention, in which the sheet 24 is folded and positioned inside the hollow cylindrical mouthpiece portion 12. In this embodiment, the innermost layer of the mouthpiece portion 12 may be formed as shown in Figures 2 to 13, or alternatively, in a different conventional manner. In other words, the innermost layer of the mouthpiece portion 12 may be configured as the sheet 24 as described herein or in a different conventional manner. The folded sheet 24 positioned inside the inner hollow cylindrical mouthpiece portion 12 may have a similar function to the sheet 24 described in relation to Figures 2 to 13. In particular, the sheet 24 may obstruct an unobstructed view of the base portion 14 of the aerosol-generating article 10 through the inner hollow mouthpiece portion 12. Furthermore, the sheet 24 may prevent unwanted particle residue from the aerosol-forming substrate of the base portion 14 from falling out of the hollow cylindrical mouthpiece portion 12. As shown in Figure 14, the sheet 24 may be advanced in an "omega" configuration. The sheet 24 may be folded at least twice, preferably at least three times, preferably at least four times, and most preferably at least five times.

[0110] Figure 15 shows the configuration of a sheet 24 having a projection 40. The projection 40 extends in a direction that is at an angle to the extension direction of the sheet 24. Due to the folding operation of the sheet 24, the projection 40 extends into the inner hollow mouthpiece portion 12. It is particularly preferable that the extension direction of the projection 40 is perpendicular to the longitudinal axis of the aerosol generating article 10. Similarly, it is preferable that the sheet 24 is folded in a direction parallel to the longitudinal axis of the aerosol generating article, so that the width direction of the sheet 24 is also parallel to the longitudinal axis of the aerosol generating article 10, while the length direction of the sheet 24 is perpendicular to the longitudinal axis of the aerosol generating article 10. The radial direction perpendicular to the longitudinal axis of the aerosol generating article 10 is shown by the line A-A' in Figure 15.

[0111] Figure 16 shows a side cross-sectional view of a sheet 24 with the same configuration as shown in Figure 15. As can be seen, the width direction of the sheet 24 extends parallel to the longitudinal axis of the aerosol generating article 10 and parallel to the flow direction of the aerosol drawn in through the mouthpiece portion 12. The flow direction of the aerosol is indicated by a dashed line. The angle at which the projection 40 extends relative to the sheet 24 is indicated by angle A. In the embodiments described herein, this angle may be greater than 20°, preferably greater than 30°, more preferably greater than 40°, and most preferably greater than 50°.

[0112] Figures 17A and 17B show potential configurations of the sheet 24 as used in Figures 15 and 16. In this configuration, a portion of the sheet 24 adjacent to the center line 44 is provided with a projection 40. Portions of the sheet 24 adjacent to both longitudinal ends are configured as projection-free portions 46. After the sheet 24 is folded and inserted into the hollow interior of the mouthpiece portion 12, the projection-free portions 46 of the sheet 24 are positioned adjacent to the inner sidewall of the mouthpiece portion 12, preferably adjacent to such an inner sidewall. The portion of the sheet 24 including the projection 40 is positioned inside the mouthpiece portion 12, as shown in Figures 15 and 16, in which case the projection 40 extends perpendicular to the longitudinal axis of the aerosol generating article 10 inside the mouthpiece portion 12. Figure 17A shows the opposite side of the sheet. The portion 46 on the upper surface without protrusions may face the inside of the mouthpiece portion 12 after the folding operation. Therefore, the portion 46 on the upper surface without protrusions may actually be provided with protrusions 40, as shown in Figure 15. However, the lower surface of the sheet 24 shown in Figure 17B may actually be characterized by a portion 46 without protrusions, because this portion is adjacent to the inner side wall of the mouthpiece portion 12 after the folding operation.

[0113] Figure 18 shows a different embodiment for forming the protrusions 40. Instead of the protrusions 40 being configured as brush bristles or similar protrusions 40, the protrusions 40 in Figure 18 are configured as flaps. These flaps are formed integrally with the sheet 24 and may also be die-cut or cut out from the sheet 24, as shown in Figure 18.

[0114] Figures 19A to 19C show the configuration of the projections 40. Figure 19A shows a rectangular projection 40 that can be formed from a sheet 24 as shown in Figure 18. Figure 19B shows a circular projection 40 that can be formed similarly to the projection 40 shown in Figure 18. Unlike the projection 40 shown in Figure 18, the circular projection 40 needs to be cut in a circular manner. Figure 19C shows a configuration of the projection 40 such that the projection 40 covers most of the cross-section inside the hollow interior of the mouthpiece portion 12. These projections 40 have a teardrop shape. Similar to the projections 40 shown in Figures 18, 19A, and 19B, these teardrop-shaped projections 40 may be formed by cutting or die-cutting the corresponding portions from the sheet 24.

Claims

1. An aerosol generating article comprising a mouthpiece portion, wherein the mouthpiece portion is hollow and cylindrical, the mouthpiece portion includes a sheet, the sheet is disposed as either or both being inside the mouthpiece portion and forming the inner side wall of the mouthpiece portion, and the sheet includes projections extending diagonally from the sheet.

2. The aerosol generating article according to claim 1, wherein the aerosol generating article further includes a base portion upstream of the mouthpiece portion.

3. The aerosol generating article according to claim 1 or 2, wherein the sheet is folded and disposed within the mouthpiece portion.

4. The aerosol generating article according to any one of claims 1 to 3, wherein the extended plane of the sheet is parallel to the longitudinal axis of the aerosol generating article.

5. The aerosol generating article according to any one of claims 1 to 4, wherein the sheet is wrapped around the mouthpiece portion to form the innermost layer.

6. The aerosol generating article according to claim 5, wherein the projection extends radially inward from the innermost layer of the mouthpiece portion.

7. An aerosol generating article according to any one of claims 1 to 6, wherein axial gaps are provided between the individual protrusions, allowing airflow through the protrusions.

8. The aerosol generating article according to any one of claims 1 to 7, wherein the sheet includes cardboard, and preferably the sheet is made from cardboard.

9. The aerosol generating article according to any one of claims 1 to 8, wherein the sheet is spirally wound around the mouthpiece portion to form the innermost layer.

10. The aerosol generating article according to claim 9, wherein the sheets are overlapped and wound spirally to form the innermost layer of the mouthpiece portion.

11. The aerosol generating article according to claim 10, wherein the overlapping portions of the sheet when rolled are covered with an adhesive.

12. The aerosol generating article according to any one of claims 1 to 11, wherein the sheet comprises at least a first sheet and an overlapping second sheet, and one or both of the first sheet and the second sheet include the protrusion.

13. The aerosol generating article according to any one of claims 1 to 12, wherein the projection has an extension direction perpendicular to the longitudinal axis of the aerosol generating article.

14. The aerosol generating article according to any one of claims 1 to 13, wherein the projection has a triangular shape, a rectangular shape, a disc shape, a teardrop shape, or a brush bristle shape.

15. A method for forming the mouthpiece portion of an aerosol generating article, - A process for providing a sheet including protrusions, - A step of wrapping the sheet around the mandrel to form the innermost layer of the hollow cylindrical mouthpiece portion, or a step of arranging the sheet inside the mouthpiece portion, A method comprising the step of extending the projection diagonally with respect to the sheet.

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