Aerosol-generating articles with downstream textiles

Abstract

The present invention relates to an aerosol generating article comprising a mouthpiece portion. The mouthpiece portion is hollow and cylindrical. The aerosol generating article further comprises a woven fabric layer. The woven fabric layer is disposed in contact with the mouthpiece portion or disposed within the mouthpiece portion. The woven fabric layer extends perpendicular to the longitudinal axis of the aerosol generating article, or the woven fabric layer is disposed at an angle to the longitudinal axis of the aerosol generating article.

Description

Technical Field

[0001] The present invention relates to aerosol-generating articles.

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 burning 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 (such as a heating chamber) of an aerosol-generating device. Due to the relatively low temperatures 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 may be unpleasant for the user. Furthermore, having an unconsolidated aerosol-forming substrate that may exit the downstream open end of the aerosol-forming article may be unpleasant for the user.

Summary of the Invention

Problems to be Solved by the Invention

[0003] [[ID=2I]] It would be desirable to have an aerosol-generating article that does not require a downstream filter. It would be desirable to have an aerosol-generating article that prevents the aerosol-forming substrate from exiting the aerosol-generating article downstream of the substrate portion of the aerosol-generating article. It would be desirable to have an aerosol-generating article that prevents the substrate portion of the aerosol-generating article from being visible in its entirety.

Means for Solving the Problems

[0004] According to one embodiment of the present invention, an aerosol generating article is provided which includes a mouthpiece portion. The mouthpiece portion may be hollow and cylindrical. The aerosol generating article may further include a woven fabric layer. The woven fabric layer may be disposed in contact with the mouthpiece portion or disposed within the mouthpiece portion. The woven fabric layer may extend perpendicular to the longitudinal axis of the aerosol generating article, or the woven fabric layer may be disposed at an angle to the longitudinal axis of the aerosol generating article.

[0005] According to one embodiment of the present invention, an aerosol generating article is provided which includes a mouthpiece portion. The mouthpiece portion is hollow and cylindrical. The aerosol generating article further comprises a woven fabric layer. The woven fabric layer is disposed in contact with the mouthpiece portion or disposed within the mouthpiece portion. The woven fabric layer extends perpendicular to the longitudinal axis of the aerosol generating article, or the woven fabric layer is disposed at an angle to the longitudinal axis of the aerosol generating article.

[0006] The woven layer may not require a downstream filter. In particular, the woven layer may prevent unsolidified residue of the aerosol-forming substrate from the aerosol-generating article from exiting the mouthpiece portion. The woven layer may have sufficient filtration effect to replace a downstream filter. This may be due to heated, non-combustible aerosol-generating articles that produce only small amounts of undesirable components that may be filtered more effectively by the woven layer.

[0007] Additionally, or alternatively, a fabric layer may prevent the substrate of the aerosol-generating article from being fully exposed. This may be desirable because users may prefer to have a clear view of the aerosol-generating article rather than directly seeing the aerosol-forming substrate when looking inside the hollow mouthpiece.

[0008] The fabric layer may be positioned in direct contact with the mouthpiece portion. In other words, other components of the aerosol generating article do not need to be positioned between the fabric layer and the mouthpiece portion.

[0009] The fabric layer may be arranged to at least partially surround the mouthpiece portion.

[0010] The fabric layer may be arranged to at least partially surround the upstream perimeter of the mouthpiece portion. The fabric layer may be arranged to partially or completely cover not only the upstream end face of the mouthpiece portion but also the upstream perimeter of the mouthpiece portion. The fabric layer may be placed over the upstream end face and upstream perimeter of the mouthpiece portion.

[0011] As an alternative to positioning the fabric layer on the upstream end face of the mouthpiece portion as described herein, the fabric layer may be positioned in a similar manner to cover the downstream end face of the mouthpiece portion.

[0012] The fabric layer may have a length and / or width that corresponds to or is greater than the outer diameter of the mouthpiece portion.

[0013] The fabric layer may be positioned in contact with the upstream end of the mouthpiece portion.

[0014] The fabric layer may be fluid permeable. In particular, the fabric layer may be permeable to volatile aerosol-forming substrates.

[0015] The fabric layer may be impermeable to the solid components of the aerosol-forming substrate.

[0016] In other words, the fabric layer may allow aerosols or volatile aerosol-forming substrates to be drawn through the fabric layer, while at the same time preventing the solid components of the aerosol-forming substrates from passing through the fabric layer.

[0017] The aerosol generating article may further comprise a substrate portion containing an aerosol-forming substrate. The substrate portion may be positioned upstream of the mouthpiece portion and upstream of the fabric layer.

[0018] The base portion may be disposed in direct contact with the fabric layer of the mouthpiece portion. In other words, the other components of the aerosol generating article do not have to be disposed between the base portion and the mouthpiece portion, specifically between the base portion and the fabric layer of the mouthpiece portion.

[0019] The fabric layer may be opaque. An opaque fabric layer may, if desired, allow for visibility of the aerosol-forming substrate portion through the fabric layer.

[0020] The fabric layer may be disc-shaped, square-shaped, or cross-shaped.

[0021] If one or both of the width and length of the woven layer correspond to the outer diameter of the mouthpiece portion, the woven layer is preferably disc-shaped. However, the woven layer may also be disc-shaped if one or both of the width and length of the woven layer are greater than the outer diameter of the mouthpiece portion. These dimensions of the woven layer are preferred when the woven layer is at least partially covering or positioned outside the upstream end face of the mouthpiece portion and the outer circumference of the mouthpiece portion adjacent to the upstream end face.

[0022] When the fabric layer is at least partially covered or disposed outside the upstream end face of the mouthpiece portion and the outer periphery of the mouthpiece portion adjacent to the upstream end face, instead of a disk-shaped fabric layer, a square-shaped or cross-shaped fabric layer may be used. Providing the fabric layer as a square-shaped or cross-shaped fabric layer may be beneficial for fixing the fabric layer around the mouthpiece portion. More specifically, the edge of the fabric layer may be fixed around the mouthpiece portion when the fabric layer is provided as a square-shaped fabric layer. When the fabric layer is provided as a cross-shaped fabric layer, the elongated "cross" portion of the fabric layer may be fixed to the outer periphery of the mouthpiece portion. Therefore, the fabric layer may be firmly held in place so as to cover the upstream end face of the mouthpiece portion. Further, wrinkles or streaks in the fabric layer may be prevented during attachment of the fabric layer to the outer periphery of the mouthpiece portion.

[0023] The thickness of the fabric layer may be substantially smaller than one or both of the length and width of the fabric layer. Exemplarily, one or both of the length and width of the fabric layer may be 10 times larger than the thickness of the fabric layer, more preferably 50 times larger, more preferably 100 times larger, and most preferably 200 times larger.

[0024] The outer diameter of the fabric layer may correspond to or be larger than the outer diameter of the mouthpiece portion. The outer diameter of the fabric layer may correspond to one or both of the width and length of the fabric layer.

[0025] The width of the fabric layer may be the same as the length of the fabric layer.

[0026] The fabric layer may be glued to the mouthpiece portion.

[0027] To facilitate the attachment of the fabric layer to the mouthpiece portion, an adhesive layer may be provided on the fabric layer. The adhesive layer may have a cross-sectional shape corresponding to the cross-sectional shape of the mouthpiece portion. Specifically, a ring-shaped adhesive layer may be provided so as to correspond to the upstream end face of the hollow cross-sectional shape of the mouthpiece portion. Instead of providing an adhesive in the form of an adhesive layer, the adhesive may be provided in the form of adhesive dots or adhesive points. These may be sufficient to fix the fabric layer to the mouthpiece portion.

[0028] When referring to the cross-sectional shape of a cross-section of a component such as a base portion, a mouthpiece portion, an adhesive layer, etc., this cross-sectional shape may be established in a plane perpendicular to the central axis in the longitudinal direction of the aerosol generating article.

[0029] Providing an adhesive layer may facilitate firmly holding the fabric layer attached to the mouthpiece portion. The adhesive layer may be provided instead of or in addition to attaching the fabric layer around the mouthpiece portion. The adhesive layer may be the only attachment means for attaching the fabric layer to the mouthpiece portion. This may particularly apply when the fabric layer has an outer diameter corresponding to the outer diameter of the upstream end face of the mouthpiece portion. If the fabric layer has a larger outer diameter (or a larger width or length), the fabric layer may be attached to the outer periphery of the mouthpiece portion. In this case, an adhesive layer may be provided to additionally fix the fabric layer to the upstream end face of the mouthpiece portion. As another method, in this case, the adhesive may be provided only on the outer periphery of the mouthpiece portion to hold the fabric layer on the outer periphery of the mouthpiece portion. In all cases considered herein where the fabric layer is attached to the outer periphery of the mouthpiece portion, this may be facilitated by a separate adhesive layer. This adhesive layer may be disposed on the outer periphery of the mouthpiece portion so that the fabric layer adheres to the outer periphery of the mouthpiece portion. As another method, the adhesive layer may be disposed on each portion of the fabric layer that contacts the outer periphery of the mouthpiece portion during the attachment of the fabric layer to the outer periphery of the mouthpiece portion.

[0030] The central portion of the fabric layer may not need to have adhesive. This may facilitate fluid permeability of the fabric layer. In other words, adhesive or an adhesive layer may be provided only in the portion of the fabric layer that is in direct contact with the mouthpiece portion (not just the hollow interior of the mouthpiece portion).

[0031] The fabric layer may be attached to the upstream end face of the mouthpiece portion, and preferably it may be bonded.

[0032] The woven layer may be configured as a mesh layer. The woven layer may consist of a single layer. Alternatively, the woven layer may comprise multiple layers.

[0033] The fabric layer may comprise individual threads. The fabric layer may be provided as a fabric with a thread pattern.

[0034] Textiles may be made from environmentally friendly and sustainable materials.

[0035] The fabric layer may have a draw resistance suitable for simulating a more conventional downstream cigarette filter. In other words, the fabric layer may have a substantially higher draw resistance than a layer through which the fluid can flow essentially unimpeded.

[0036] The fabric layer may be a colored fabric layer. The color of the fabric layer may be visible to the user when viewed through the hollow mouthpiece portion. The color of the fabric layer may indicate the type of aerosol-forming substrate of the aerosol-generating article.

[0037] The mouthpiece portion may be provided as a cardboard tube, apart from the woven fabric layer. The side walls of the mouthpiece portion may be made of cardboard. The mouthpiece portion may consist only of side walls made of cardboard, apart from the woven fabric layer, and may not have any further elements.

[0038] The fabric layer may have the same cross-sectional shape as the mouthpiece portion.

[0039] The woven fabric layer may be wrapped at least partially around the mouthpiece portion, or it may be placed over the mouthpiece portion. In this case, preferably only the upstream portion of the outer circumference of the mouthpiece portion is covered by the woven fabric layer.

[0040] The fabric layer may have a circumferential pocket or groove into which the upstream end face of the mouthpiece portion may be slotted.

[0041] The circumferential groove may also be ring-shaped. The cross-sectional shape of the circumferential groove may correspond to the cross-sectional shape of the upstream end face of the mouthpiece portion.

[0042] The fabric layer may be arranged across the mouthpiece portion. Specifically, the hollow shape of the mouthpiece portion connects to a hollow core of the mouthpiece portion. The fabric layer may be arranged across this hollow core. In other words, the fabric layer may be arranged to cover the hollow core of the mouthpiece portion. As described herein, the arrangement of the fabric layer may be similar to that of a lid closing a wide-mouthed bottle.

[0043] A portion of the woven fabric layer extending over the hollow core may be planar. When the outer periphery of the woven fabric layer corresponds to the outer periphery of the mouthpiece portion, preferably the entire woven fabric layer is planar. When the woven fabric layer is placed over the mouthpiece portion, at least a portion of the woven fabric layer extending over the hollow core of the mouthpiece portion may be planar.

[0044] In an alternative embodiment, a portion of the fabric layer extending over the hollow core may be angled with respect to the longitudinal central axis of the aerosol-generating article. This embodiment is particularly preferred when the upstream end face of the mouthpiece portion is provided with a circumferential groove in the fabric layer into which it may be slotted. In this case, a portion of the fabric layer extending over the hollow core of the mouthpiece portion may be provided with a conical shape. A portion of the conical shape of the fabric layer may abut the circumferential groove. A portion of the conical shape of the fabric layer may form the central part of the fabric layer. A portion of the conical shape of the fabric layer may be arranged to penetrate into the hollow core of the mouthpiece portion. In other words, the fabric layer may be provided by sewing or gluing the edges of the fabric layer together to form a “pocket” such that the edge of the pocket is rolled up onto the outer surface of the mouthpiece portion.

[0045] The aerosol generating article may further comprise a cardboard tube. The cardboard tube may have an outer diameter that corresponds to the inner diameter of the mouthpiece portion, or an outer diameter that is smaller than the inner diameter of the mouthpiece portion. The fabric layer may be disposed in contact with or covering the upstream end face of the cardboard tube. The cardboard tube may be disposed inside the mouthpiece portion. The cardboard tube may be glued inside the mouthpiece portion, or it may be attached inside the mouthpiece portion by a rib fit.

[0046] The cardboard tube may assist in positioning the fabric layer over the mouthpiece portion. This embodiment is essentially an alternative to gluing the fabric layer to the upstream end face of the mouthpiece portion, or to covering the upstream end face and outer circumference of the mouthpiece portion with the fabric layer. The cardboard tube may prevent any deformation of the external shape of the aerosol-generating article due to the positioning of the fabric layer on the outer circumference of the mouthpiece portion. As a further advantage, the cardboard tube may be positioned at any desired position within the hollow interior of the mouthpiece portion. In other words, the positioning of the cardboard tube within the mouthpiece portion is not limited to positioning it over the upstream end face of the mouthpiece portion.

[0047] The cardboard tube may have a tubular shape. The cardboard tube may have a length substantially less than the length of the mouthpiece portion. The length of the cardboard tube and the length of the mouthpiece portion may be measured along the central axis of the long axis of the aerosol generating article.

[0048] The woven layer may be glued to the upstream end face of the cardboard tube in the same manner as described herein with respect to gluing the woven layer to the upstream end face of the mouthpiece portion. Similarly, the woven layer may be placed over the upstream end face of the cardboard tube and the outer circumference of the cardboard tube in the same manner as described herein with respect to gluing the woven layer over the upstream end face of the mouthpiece portion and the outer circumference of the mouthpiece portion.

[0049] After the fabric layer is attached to the cardboard tube, the cardboard tube may be fixed inside the mouthpiece section.

[0050] The mouthpiece portion may be glued to the base portion. Alternatively, wrapping paper or chipping paper may be arranged to surround at least a portion of the mouthpiece portion and at least a portion of the base portion, thereby attaching the mouthpiece portion and the base portion together.

[0051] The present invention further relates to a method for attaching a woven fabric layer as described herein to a mouthpiece portion as described herein. The present invention further relates to a method for attaching a woven fabric layer as described herein to a cardboard tube as described herein. The present invention further relates to one or more of the steps of attaching a woven fabric layer to a mouthpiece portion, attaching a woven fabric layer to a cardboard tube, attaching a mouthpiece portion comprising a woven fabric layer to a base portion, and attaching a cardboard tube to a mouthpiece portion.

[0052] The aerosol generating article may be used in an aerosol generating device. The aerosol generating article may be inserted into a cavity in the aerosol generating device. The aerosol generating device may heat the aerosol-forming substrate of the aerosol generating article, thereby producing an inhalable aerosol.

[0053] As used herein, the terms “proximal,” “distal,” “downstream,” and “upstream” are used to describe the relative position of a component or part of a component of an aerosol generator with respect to the direction in which the user inhales the aerosol generator during use.

[0054] An aerosol generator may have a mouth end through which, during use, the aerosol exits the aerosol generator and is delivered to the user. The mouth end may also be called the proximal end. During use, the user inhales the proximal or mouth end of the aerosol generator to inhale the aerosol generated by the aerosol generator. Alternatively, the user may inhale directly 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. An aerosol generator has a distal end opposite to the proximal or mouth end. The proximal or mouth end 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. Components of an aerosol generator, or parts of components, may be described as being upstream or downstream of each other based on their relative positions between the proximal, downstream, or mouth end of the aerosol generator and the distal or upstream end of the aerosol generator.

[0055] 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.

[0056] The term “smoking” as used herein in relation to the present invention, relating to an apparatus, article, system, substrate, or other, 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 arranged 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 to form an inhalable aerosol.

[0057] 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 supply of power to a heating element. Power may be supplied to the heating element continuously following the startup of the aerosol generator, or intermittently (e.g., with each smoke inhalation). 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, control the power supply to the heating element in accordance with the electrical resistance of the heating element.

[0058] The aerosol generator may have a power source (typically a battery) within 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 (e.g., a lithium-cobalt battery, a lithium iron phosphate battery, a lithium titanate battery, or a 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 about 6 minutes, or for a time period that is a multiple of 6 minutes. In another embodiment, the power source may have a capacity sufficient to provide a predetermined number of fume extractions or discontinuous activation of a heating element.

[0059] 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 opposite the open end. The closed end may be the base of the cavity. The closed end may be closed except for providing an air opening located 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 longitudinal axis. The longitudinal axis may be a direction extending between the open end and the closed end along the longitudinal axis. The longitudinal axis of the cavity may be parallel to the longitudinal axis of the aerosol generator.

[0060] 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.

[0061] The airflow channel may extend through the cavity. Ambient air may be drawn through the airflow channel into the aerosol generator, into the cavity, and toward the user. Downstream of the cavity, a mouthpiece may be provided, or the user may inhale the aerosol generating article directly. The airflow channel may extend through the mouthpiece.

[0062] 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 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, encapsulated in, or coated with an insulating material, depending on the required energy transfer dynamics and external physicochemical properties, or vice versa.

[0063] As described, in any aspect of the present 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 an internal and an external heating element, 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 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 placed in or on a rigid carrier material. In one such 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 ceramic material and then sandwiched between other insulating materials such as glass. The heater thus formed may be used during operation for both heating the heating element and monitoring its temperature.

[0064] The external heating element may take any suitable 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 around the periphery of the substrate receiving cavity. Alternatively, the external heating element may take the form of a metal grid, flexible printed circuit board, molded circuit component (MID), ceramic heater, flexible carbon fiber heater, or be formed on a substrate of suitable 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 exemplary devices, the metal may be formed as a track between two layers of suitable insulating material. The external heating element thus formed may be used during operation for both heating the external heating element and monitoring its temperature.

[0065] 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 has the ability to generate heat when penetrated by an alternating magnetic field. When located within an alternating magnetic field, if the susceptor is conductive, eddy currents are typically induced by the alternating magnetic field. If the susceptor is magnetic, another effect that typically contributes 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 inductive magnetic fields. Another effect that contributes to hysteresis loss is when magnetic domains expand or contract within the susceptor. Generally, all these changes occurring at or below the nanoscale 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 will contribute to the heating of the susceptor. If the susceptor is magnetic but not conductive, hysteresis loss will be the only means by which the susceptor will be 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 so that an aerosol is formed. Heat transfer may also be mainly by thermal conduction. Such heat transfer is best when the susceptor is in close thermal contact with the aerosol-forming substrate.

[0066] As used herein, the term "aerosol-generating article" refers to an article comprising an aerosol-forming substrate having the ability to release volatile compounds capable of forming aerosols. 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. Aerosol-generating articles may be disposable.

[0067] As used herein, the term “aerosol-forming substrate” refers to a substrate having the ability to release one or more volatile compounds capable of forming aerosols. Such 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.

[0068] The aerosol-forming substrate may be a solid aerosol-forming substrate. The aerosol-forming substrate may be disposed within the substrate portion. The aerosol-forming substrate may contain both solid and liquid components. The aerosol-forming substrate may contain tobacco-containing material containing volatile tobacco-flavored compounds released from the substrate upon heating. The aerosol-forming substrate may contain non-tobacco material. The aerosol-forming substrate may contain an aerosol-forming agent that facilitates the formation of a high-density, stable aerosol. Examples of suitable aerosol-forming agents are glycerin and propylene glycol.

[0069] The aerosol generating substrate preferably comprises homogenized tobacco material, an aerosol forming agent, 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 grinding the tobacco leaves, which allows for more effective release of nicotine and flavor during heating.

[0070] A non-exclusive list of non-limiting embodiments is provided below. One or more features of these embodiments may be combined with one or more features of other embodiments, forms, or aspects described herein.

[0071] Example 1. A mouthpiece portion, which is hollow and cylindrical, A woven fabric layer, An aerosol generating article in which a woven fabric layer is disposed in contact with or within the mouthpiece portion, and the woven fabric layer extends perpendicularly to the longitudinal axis of the aerosol generating article, or the woven fabric layer is disposed at an angle to the longitudinal axis of the aerosol generating article. Example 2. An aerosol generating article according to Example 1, wherein the fabric layer is disposed in direct contact with the mouthpiece portion. Example 3. An aerosol generating article according to any one of Examples 1 to 2, wherein the fabric layer is arranged to at least partially surround the mouthpiece portion. Example 4. An aerosol generating article according to any one of Examples 1 to 3, wherein the fabric layer is disposed in contact with the upstream end of the mouthpiece portion. Example 5. An aerosol-generating article according to any one of Examples 1 to 4, wherein the fabric layer is fluid-permeable. Example 6. An aerosol-generating article according to any one of Examples 1 to 5, wherein the fabric layer is impermeable to the solid components of the aerosol-forming substrate. Example 7. An aerosol generating article according to any one of Examples 1 to 6, wherein the aerosol generating article further comprises a base portion including an aerosol-forming substrate, and the base portion is disposed upstream of the mouthpiece portion and upstream of the fabric layer. Example 8. An aerosol-generating article according to any one of Examples 1 to 7, wherein the fabric layer is opaque. Example 9. An aerosol-generating article according to any one of Examples 1 to 8, wherein the fabric layer is disc-shaped, square-shaped, or cross-shaped. Example 10. An aerosol-generating article according to any one of Examples 1 to 9, wherein the outer diameter of the fabric layer corresponds to or is greater than the outer diameter of the mouthpiece portion. Example 11. An aerosol-generating article according to any one of Examples 1 to 10, wherein the fabric layer is glued to the mouthpiece portion. Example 12. An aerosol generating article according to any one of Examples 1 to 11, wherein the fabric layer is attached, preferably glued, to the upstream end face of the mouthpiece portion. Example 13. An aerosol generating article according to any one of Examples 1 to 12, wherein the fabric layer has the same cross-sectional shape as the mouthpiece portion. Example 14. An aerosol-generating article according to any one of Examples 1 to 13, wherein the fabric layer is at least partially wrapped around the mouthpiece portion. Example 15. An aerosol generating article according to any one of Examples 1 to 14, wherein the fabric layer comprises a circumferential pocket or groove into which the upstream end face of the mouthpiece portion is slotted. Example 16. An aerosol generating article according to any one of Examples 1 to 15, wherein the aerosol generating article further comprises a cardboard tube, the cardboard tube having an outer diameter corresponding to or smaller than the inner diameter of the mouthpiece portion, the fabric layer being disposed in contact with or covering the upstream end face of the cardboard tube, and the cardboard tube being disposed within the mouthpiece portion, preferably the cardboard tube being glued to the inside of the mouthpiece portion or fitted inside the mouthpiece portion by a treadmill.

[0072] Features described in relation to one embodiment may be equally applicable to other embodiments of the present invention.

[0073] The present invention will be further explained with reference to the following attached drawings, which are for illustrative purposes only. [Brief explanation of the drawing]

[0074] [Figure 1] Figure 1 shows a disassembled and assembled side view of the aerosol generating article according to the present invention. [Figure 2] Figure 2 shows a first embodiment of the woven fabric layer in the mouthpiece portion of the aerosol generating article. [Figure 3] Figure 3 shows the attachment of the fabric layer to the mouthpiece portion in the first embodiment. [Figure 4] Figure 4 shows a second embodiment of the fabric layer in the mouthpiece portion of the aerosol generating article. [Figure 5] Figure 5 shows the attachment of the fabric layer to the mouthpiece portion in the second embodiment. [Figure 6]Figure 6 shows an alternative shape of the fabric layer used in the second embodiment. [Figure 7] Figure 7 shows the attachment of the fabric layer in an alternative shape to that shown in Figure 6 in the second embodiment. [Figure 8] Figure 8 shows a third embodiment of the fabric layer in the mouthpiece portion of the aerosol generating article. [Figure 9] Figure 9 shows the attachment of the fabric layer to the mouthpiece portion in the third embodiment. [Figure 10] Figure 10 shows a fourth embodiment of the fabric layer of the mouthpiece portion of the aerosol generating article. [Figure 11] Figure 11 shows the attachment of the fabric layer to the mouthpiece portion in the fourth embodiment. [Modes for carrying out the invention]

[0075] Figure 1 shows an aerosol generating article 10. The aerosol generating article 10 comprises several components. The components shown in Figure 1 are a mouthpiece portion 12, a fabric layer 14 of the mouthpiece portion 12, a base portion 16, a front plug 18, and an optional portion 20. The front plug 18, the base portion 16, and the optional portion 20 are attached together with wrapping paper 22. The optional portion 20 and the mouthpiece portion 12, including the fabric layer 14, are attached together using chipping paper 24. The optional portion 20 can be omitted so that the mouthpiece portion 12 is in direct contact with the base portion 16. The optional portion 20 may be provided as a cooling portion that enables the formation of an inhalable aerosol, the condensation of droplets of volatile aerosol-forming substrate, and a cooling portion.

[0076] The downstream direction 26 is indicated by an arrow in Figure 1. The user may inhale the aerosol generated in the aerosol generating article 10 downstream of the aerosol generating article 10. The user may also hold the mouthpiece portion 12 between their lips and inhale the aerosol directly from the mouthpiece portion 12.

[0077] Figure 2 shows the fabric layer 14 and the upstream portion 28 of the mouthpiece portion 12 in more detail. Specifically, Figure 2 shows the fabric layer 14 before it is attached to the mouthpiece portion 12. The fabric layer 14 has a circular cross-section. The outer diameter of the fabric layer 14 corresponds to the outer diameter of the mouthpiece portion 12. The fabric layer 14 is attached to the mouthpiece portion 12 by gluing the fabric layer 14 to the upstream end face 30 of the mouthpiece portion 12.

[0078] The adhesive may be provided in the form of a ring of adhesive corresponding to the cross-sectional shape of the hollow mouthpiece portion 12. In other words, the central portion of the fabric layer 14 is left without adhesive to allow fluid permeability of the fabric layer 14. Alternatively, instead of providing the adhesive in the form of a ring-shaped adhesive layer on the fabric layer 14 or on the upstream end face 30 of the mouthpiece portion 12, the adhesive may be provided as adhesive dots or adhesive patches 40es on the fabric layer 14 or on the upstream end face 30 of the mouthpiece portion 12.

[0079] Figure 3 shows the fabric layer 14 of Figure 2 attached to the mouthpiece portion 12. Thus, the mouthpiece portion 12 is constructed with a closed upstream end face 30. Due to the hollow nature of the mouthpiece portion 12, it comprises a hollow core 32. The fabric layer 14 allows airflow through the mouthpiece portion 12, as indicated by the arrows. At the same time, the fabric layer 14 prevents large particles of the aerosol-forming substrate from reaching the hollow core 32 of the mouthpiece portion 12. These large particles of the aerosol-forming substrate are prevented from reaching the user's mouth, which may be undesirable.

[0080] Figure 4 shows a further embodiment of the woven layer 14. In the embodiment shown in Figure 4, the woven layer 14 has a square cross-section. The length 34 and width 36 of the woven layer 14 are each greater than the outer diameter of the mouthpiece portion 12.

[0081] As shown in Figure 5, this also allows the woven fabric layer 14 to be placed over the upstream end surface 30 of the mouthpiece portion 12, covering the outer circumference 38 of the mouthpiece portion 12. Furthermore, Figure 5 shows adhesive patches 40 that firmly hold the woven fabric layer 14 to the outer circumference 38 of the upstream portion 28 of the mouthpiece portion 12. The number of adhesive patches 40es is, of course, merely exemplary and may vary depending on the situation.

[0082] Figure 6 shows one embodiment of the woven layer 14 in which the woven layer 14 is cross-shaped. As a result, the woven layer 14 comprises a “cross” portion or legs 42. These legs 42 are created by providing a notch 44 in which the woven layer 14 is absent. As shown by the circular dashed line in Figure 6, the notch 44 is dimensioned so that the woven layer 14 can cover the upstream end face 30 of the mouthpiece portion 12.

[0083] Figure 7 shows the attachment of the cross-shaped fabric layer 14 of Figure 6 to the upstream end face 30 of the mouthpiece portion 12. The legs 42 of the fabric layer 14 are attached to the outer circumference 38 of the mouthpiece portion 12 using adhesive patches 40es. This arrangement of the fabric layer 14 creates a firm connection between the fabric layer 14 and the mouthpiece portion 12, while simultaneously preventing creasing or folds in the area where the fabric layer 14 covers the outer circumference 38 of the mouthpiece portion 12.

[0084] Figure 8 shows a further embodiment of the woven layer 14. In this embodiment, the woven layer 14 has a circumferential groove 46 into which the upstream end face 30 of the mouthpiece portion 12 can be slotted. The central part of the woven layer 14 has a conical shape 48 so that the central part of the woven layer 14 can be inserted into the hollow core 32 of the mouthpiece portion 12. Due to the slotting action of the upstream end face 30 of the mouthpiece portion 12 into the circumferential groove 46 of the woven layer 14, the woven layer 14 can be securely attached to the mouthpiece portion 12. At the same time, an overlap is created between the outer edge of the woven layer 14 and the outer circumference 38 of the mouthpiece portion 12.

[0085] Figure 9 shows the insertion of the woven fabric layer 14 into the conical interior of the hollow core 32 of the mouthpiece portion 12. At the same time, the outer edge of the woven fabric layer 14 can be attached to the outer circumference 38 of the mouthpiece portion 12, preferably by gluing.

[0086] Figure 10 shows a further embodiment in which the fabric layer 14 is attached to a cardboard tube 50 before being attached to the mouthpiece portion 12. The cardboard tube 50 has an outer diameter corresponding to, or slightly smaller than, the inner diameter of the mouthpiece portion 12. The fabric layer 14 is attached to the upstream end face of the cardboard tube 50. The attachment of the fabric layer 14 to the upstream end face of the cardboard tube 50 may be similar to that described herein with respect to the attachment of the fabric layer 14 to the upstream end face 30 of the mouthpiece portion 12. In the embodiment shown in Figure 10, the attachment of the fabric layer 14 to the upstream end face of the cardboard tube 50 may be similar to the attachment of the fabric layer 14 to the upstream end face 30 of the mouthpiece portion 12 shown in Figure 5. After the fabric layer 14 is attached to the upstream end face of the cardboard tube 50, the cardboard tube 50 can be inserted into the hollow core 32 of the mouthpiece portion 12.

[0087] Figure 11 shows the arrangement of a cardboard tube 50 with a woven fabric layer 14 inside the hollow core 32 of the mouthpiece portion 12. This embodiment may facilitate particularly secure retention of the woven fabric layer 14 inside the mouthpiece portion 12. Furthermore, the placement of the woven fabric layer 14 within the mouthpiece portion 12 can be flexibly adjusted downstream or upstream as desired. Ultimately, the appearance of the aerosol-generating article 10 is not obstructed by the woven fabric layer 14, which may potentially be a problem when the woven fabric layer 14 is positioned on the outer circumference 38 of the mouthpiece portion 12.

Claims

1. The mouthpiece portion, which is hollow and cylindrical, A woven layer, An aerosol generating article in which the woven fabric layer is disposed in contact with the mouthpiece portion or disposed within the mouthpiece portion, and the woven fabric layer extends perpendicular to the longitudinal axis of the aerosol generating article, or the woven fabric layer is disposed at an angle to the longitudinal axis of the aerosol generating article, and the woven fabric layer is disposed to at least partially surround the mouthpiece portion.

2. The aerosol generating article according to claim 1, wherein the fabric layer is disposed in direct contact with the mouthpiece portion.

3. The aerosol generating article according to claim 1 or claim 2, wherein the fabric layer is disposed in contact with the upstream end of the mouthpiece portion.

4. The aerosol generating article according to any one of claims 1 to 3, wherein the fabric layer is fluid permeable.

5. The aerosol generating article according to any one of claims 1 to 4, wherein the fabric layer is impermeable to the solid components of the aerosol-forming substrate.

6. The aerosol generating article according to any one of claims 1 to 5, further comprising a base portion including an aerosol-forming substrate, wherein the base portion is disposed upstream of the mouthpiece portion and upstream of the fabric layer.

7. The aerosol generating article according to any one of claims 1 to 6, wherein the fabric layer is opaque.

8. The aerosol generating article according to any one of claims 1 to 7, wherein the outer diameter of the fabric layer corresponds to or is greater than the outer diameter of the mouthpiece portion.

9. The aerosol generating article according to any one of claims 1 to 8, wherein the fabric layer is glued to the mouthpiece portion.

10. The aerosol generating article according to any one of claims 1 to 9, wherein the fabric layer is attached to the upstream end face of the mouthpiece portion, preferably by gluing.

11. The aerosol generating article according to any one of claims 1 to 10, wherein the fabric layer has the same cross-sectional shape as the mouthpiece portion.

12. The aerosol generating article according to any one of claims 1 to 11, wherein the fabric layer is at least partially wrapped around the mouthpiece portion.

13. The aerosol generating article according to any one of claims 1 to 12, wherein the fabric layer comprises a circumferential pocket or groove into which the upstream end face of the mouthpiece portion is slotted.

14. The aerosol generating article according to any one of claims 1 to 13, wherein the aerosol generating article further comprises a cardboard tube, the cardboard tube having an outer diameter corresponding to or smaller than the inner diameter of the mouthpiece portion, the fabric layer being disposed in contact with or covering the upstream end face of the cardboard tube, and the cardboard tube being disposed within the mouthpiece portion, preferably the cardboard tube being glued to the inside of the mouthpiece portion or fitted into the inside of the mouthpiece portion.

Images