Improved upstream elements

Abstract

An upstream element (20) for an aerosol-generating article (10). The upstream element (20) is formed of a nonwoven material. The upstream element (20) includes particle-holding features comprising a plurality of longitudinal folds. Each longitudinal fold is spaced 25 to 1000 micrometers apart from its adjacent longitudinal folds. Each longitudinal fold has a height corresponding to the distance between adjacent longitudinal folds, which is also 25 to 1000 micrometers.

Description

Technical Field

[0001] The present disclosure relates to an upstream element for an aerosol generating article. The present disclosure also relates to a method of manufacturing the upstream element. The present disclosure also relates to an aerosol generating article comprising an aerosol generating substrate for generating an inhalable aerosol upon heating, and an aerosol generating device configured to heat the aerosol generating substrate of the aerosol generating article.

Background Art

[0002] Aerosol generating articles in which an aerosol generating substrate containing an aerosol generating material such as a tobacco-containing material is heated rather than burned are known in the art.

[0003] Typically, in a heated aerosol generating article, the aerosol is generated by the transfer of heat to an aerosol generating substrate physically separated from the heat source. In use, the volatile compounds are released from the aerosol generating substrate by the transfer of heat from the heat source to the aerosol generating substrate and entrained in the air drawn through the aerosol generating article. As the released compounds cool, they condense to form an aerosol inhaled by the user.

[0004] One known type of heated aerosol generating article, commonly referred to as a heat-not-burn tobacco product or a heated tobacco product, comprises a solid aerosol generating substrate comprising a tobacco material, which is heated to produce an inhalable aerosol.

[0005] Numerous handheld aerosol generators configured to heat the aerosol generating substrate of a heated aerosol generating article are known in the art. These include electrically operated aerosol generators in which an aerosol is generated by the transfer of heat from one or more electric heating elements of the aerosol generator to the aerosol generating substrate of the heated aerosol generating article. Known handheld electrically operated aerosol generators typically comprise a battery, control electronics, and one or more electric heating elements for heating the aerosol generating substrate of a heated aerosol generating article, which are specifically designed for use with the aerosol generator.

[0006] Some known electrically heated aerosol generators include an internal heating element configured to be inserted into the aerosol generating substrate of a heated aerosol generating article. For example, International Publication No. 2013 / 098410 discloses an aerosol generating system comprising an aerosol generating article and an electrically operated aerosol generating device having a heating element in the form of a blade inserted into the aerosol generating substrate of the aerosol generating article.

[0007] Other known electrically operated aerosol generators include one or more external heating elements. For example, International Publication No. 2020 / 115151 discloses an aerosol generating system comprising an aerosol generating article and an electrically operated aerosol generator having external heating elements surrounding the aerosol generating article.

[0008] Electrically operated aerosol generators are also known, which include an inductor configured to inductively heat the aerosol generating substrate of a heated aerosol generating article. For example, International Publication No. 2015 / 176898 discloses an aerosol generating system comprising an aerosol generating article comprising an elongated susceptor in thermal contact with an aerosol generating substrate and an electrically operated aerosol generator having an inductor for heating the aerosol generating substrate. During use, a fluctuating or alternating electromagnetic field generated by the inductor induces eddy currents within the susceptor, causing heating of the susceptor as a result of either or both resistive losses (Joule heating) and / or hysteresis losses (if the susceptor is magnetic). The heat generated within the susceptor is transferred to the aerosol generating substrate by conduction.

[0009] It is known that the aerosol-generating substrate of an aerosol-generating article may absorb water from the air, for example, during storage. The aerosol-generating substrate may absorb water from the air until it reaches an equilibrium point, at which point the water content of the aerosol-generating substrate may be equal to the relative humidity of the environment.

[0010] Heating the aerosol-generating substrate during use of an aerosol-generating article can, for example, lead to the evaporation of absorbed water before the evaporation of nicotine and glycerin within the aerosol-generating substrate. The resulting water vapor can carry a considerable amount of energy and may also increase the temperature of the aerosol delivered to the user. This can result in an unpleasant sensory experience for the user, at least during the initial inhalation. This phenomenon is called "warm aerosol perception" and can be particularly problematic in warm and humid environments. In some cases, warm aerosol perception may deter users from using the aerosol-generating article.

[0011] Aerosol-generating articles having upstream elements are known. Some known aerosol-generating articles have upstream elements in the form of a cellulose acetate tow plug.

[0012] Many countries impose restrictions on the use of single-use plastic products.

[0013] Therefore, it is desirable to provide upstream elements for aerosol-generating articles that are more sustainable, ensure a good sensory experience for the user, and maintain the quality of the aerosols delivered to the user compared to known aerosol-generating articles. [Overview of the project]

[0014] This disclosure relates to an upstream element for an aerosol-generating article. The upstream element may be formed of a nonwoven material. The upstream element may be formed of an airlaid nonwoven material.

[0015] According to one aspect of the present invention, an upstream element for an aerosol-generating article is provided, the upstream element being formed of an airlaid nonwoven material.

[0016] Advantageously, the formation of upstream elements from airlaid nonwoven materials allows for the production of more sustainable upstream elements from, for example, natural or biodegradable materials, without compromising the functional and mechanical properties of the upstream elements.

[0017] The airlaid nonwoven material may contain cellulose fibers. The airlaid nonwoven material may contain at least 90 weight percent cellulose. The airlaid nonwoven material may contain at least 95 weight percent cellulose. The airlaid nonwoven material may contain at least 99 weight percent cellulose. The airlaid nonwoven material may contain 100 weight percent cellulose.

[0018] Advantageously, upstream elements are formed from more sustainable materials without compromising the functional properties or manufacturability of the upstream elements.

[0019] The airlaid nonwoven material may include a fibrous web material. The airlaid nonwoven material may include a bonded web. The bonded web may be a high-pressure bonded web. The bonded web may be a hydroentangled web.

[0020] Advantageously, the inclusion of the combined web enables the manufacture of upstream elements that possess the required functional properties, such as the hardness needed for stick insertion to ensure the resilience of consumables when inserted into the aerosol generator during the combination process or into the final configuration of the stick.

[0021] The airlaid nonwoven material may have a weight of at least 15 grams per square meter of surface area. The airlaid nonwoven material may have a weight of at least 30 grams per square meter of surface area. The airlaid nonwoven material may have a weight of at least 50 grams per square meter of surface area. The airlaid nonwoven material may have a weight of at least 60 grams per square meter of surface area.

[0022] The airlaid nonwoven material may have a weight of up to 600 grams per square meter of surface area. The airlaid nonwoven material may have a weight of up to 200 grams per square meter of surface area. The airlaid nonwoven material may have a weight of up to 70 grams per square meter of surface area.

[0023] The airlaid nonwoven material may have a weight per square meter of 15 grams to 600 grams per square meter. The airlaid nonwoven material may have a weight per square meter of 30 grams to 200 grams per square meter. The airlaid nonwoven material may have a weight per square meter of 60 grams to 180 grams per square meter.

[0024] The airlaid nonwoven material may have a weight per surface area of 62 grams per square meter.

[0025] The airlaid nonwoven material may have a weight per surface area of 170 grams per square meter.

[0026] Advantageously, the areal density of the airlaid nonwoven material enables the manufacture of upstream elements having the property of ensuring that the required functional characteristics, such as the required pressure drop, for example the pressure drop required to ensure proper aerosol delivery, are achieved.

[0027] The airlaid nonwoven material may be a sheet. The sheet may have a bobbin width of at least 400 millimeters. The sheet may have a bobbin width of at most 500 millimeters. The sheet may have a bobbin width of from 400 millimeters to 500 millimeters.

[0028] The sheet may have a bobbin width of at least 120 millimeters. The sheet may have a bobbin width of at most 210 millimeters. The sheet may have a bobbin width of from 120 millimeters to 210 millimeters.

[0029] Advantageously, the bobbin width is selected to ensure the manufacture of upstream elements having the property of achieving the required functional characteristics, such as the required pressure drop, for example the pressure drop required to ensure proper aerosol delivery.

[0030] The upstream element may be formed of the airlaid nonwoven material.

[0031] According to one aspect of the invention, an upstream element for an aerosol-generating article is provided, the upstream element being formed of the airlaid nonwoven material.

[0032] Advantageously, the formation of the upstream element from the airlaid nonwoven material enables a more sustainable manufacture of the upstream element, for example from natural or biodegradable materials, without impairing the functional and mechanical properties of the upstream element.

[0033] The airlaid nonwoven material may contain cellulose fibers. The airlaid nonwoven material may contain at least 90 weight percent cellulose. The airlaid nonwoven material may contain at least 95 weight percent cellulose. The airlaid nonwoven material may contain at least 99 weight percent cellulose. The airlaid nonwoven material may contain 100 weight percent cellulose.

[0034] Advantageously, upstream elements are formed from more sustainable materials without compromising the functional properties or manufacturability of the upstream elements.

[0035] The airlaid nonwoven material may include a fibrous web material. The airlaid nonwoven material may include a bonded web. The bonded web may be a high-pressure bonded web. The bonded web may be a hydroentangled web.

[0036] Advantageously, the inclusion of the combined web enables the manufacture of upstream elements that possess the required functional properties, such as the hardness needed for stick insertion to ensure the resilience of consumables when inserted into the aerosol generator during the combination process or into the final configuration of the stick.

[0037] The airlaid nonwoven material may have a weight of at least 15 grams per square meter of surface area. The airlaid nonwoven material may have a weight of at least 30 grams per square meter of surface area. The airlaid nonwoven material may have a weight of at least 50 grams per square meter of surface area. The airlaid nonwoven material may have a weight of at least 60 grams per square meter of surface area.

[0038] The airlaid nonwoven material may have a weight of up to 600 grams per square meter of surface area. The airlaid nonwoven material may have a weight of up to 200 grams per square meter of surface area. The airlaid nonwoven material may have a weight of up to 70 grams per square meter of surface area.

[0039] The airlaid nonwoven material may have a weight per square meter of 15 grams to 600 grams per square meter. The airlaid nonwoven material may have a weight per square meter of 30 grams to 200 grams per square meter. The airlaid nonwoven material may have a weight per square meter of 60 grams to 180 grams per square meter.

[0040] The airlaid nonwoven material may have a weight of 62 grams per square meter of surface area.

[0041] The airlaid nonwoven material may have a weight of 170 grams per square meter of surface area.

[0042] Advantageously, the area density of airlaid nonwoven materials enables the manufacture of upstream elements that have required functional properties, such as the required pressure drop, for example, the pressure drop necessary to ensure proper aerosol delivery.

[0043] The airlaid nonwoven material may be in the form of a sheet. The sheet may have a bobbin width of at least 400 mm. The sheet may have a bobbin width of up to 500 mm. The sheet may have a bobbin width of 400 mm to 500 mm.

[0044] The sheet may have a bobbin width of at least 120 mm. The sheet may have a bobbin width of up to 210 mm. The sheet may have a bobbin width of 120 mm to 210 mm.

[0045] Advantageously, the bobbin width is selected to ensure the manufacture of upstream elements that have the required functional characteristics, such as the required pressure drop, for example, the pressure drop necessary to ensure proper aerosol delivery.

[0046] In an alternative embodiment of the present invention, the upstream element may be formed from a wet-laid nonwoven material.

[0047] According to one aspect of the present invention, an upstream element for an aerosol-generating article is provided, the upstream element being formed of a wet-laid nonwoven material.

[0048] Advantageously, the formation of upstream elements from wet-laid nonwoven materials allows for the production of more sustainable upstream elements from, for example, natural or biodegradable materials, without compromising the functional and mechanical properties of the upstream elements.

[0049] The wet-laid nonwoven material may contain cellulose fibers. The wet-laid nonwoven material may contain at least 90 weight percent of cellulose. The wet-laid nonwoven material may contain at least 95 weight percent of cellulose. The wet-laid nonwoven material may contain at least 99 weight percent of cellulose. The wet-laid nonwoven material may contain 100 weight percent of cellulose.

[0050] Advantageously, upstream elements are formed from more sustainable materials without compromising the functional properties or manufacturability of the upstream elements.

[0051] The wet-laid nonwoven material may include a fibrous web material. The wet-laid nonwoven material may include a bonded web. The bonded web may be a high-pressure bonded web. The bonded web may be a hydro-entangled web.

[0052] Advantageously, the inclusion of the combined web enables the manufacture of upstream elements that possess the required functional properties, such as the hardness needed for stick insertion to ensure the resilience of consumables when inserted into the aerosol generator during the combination process or into the final configuration of the stick.

[0053] The wet-laid nonwoven material may have a weight of at least 15 grams per square meter of surface area. The air-laid nonwoven material may have a weight of at least 30 grams per square meter of surface area. The wet-laid nonwoven material may have a weight of at least 50 grams per square meter of surface area. The wet-laid nonwoven material may have a weight of at least 60 grams per square meter of surface area.

[0054] The wet-laid nonwoven material may have a weight of up to 600 grams per square meter of surface area. The wet-laid nonwoven material may have a weight of up to 200 grams per square meter of surface area. The wet-laid nonwoven material may have a weight of up to 70 grams per square meter of surface area.

[0055] The wet-laid nonwoven material may have a weight per square meter of 15 grams to 600 grams per square meter. The wet-laid nonwoven material may have a weight per square meter of 30 grams to 200 grams per square meter. The wet-laid nonwoven material may have a weight per square meter of 60 grams to 180 grams per square meter.

[0056] The wet-laid nonwoven material may have a weight of up to 62 grams per square meter of surface area.

[0057] The wet-laid nonwoven material may have a weight of up to 170 grams per square meter of surface area.

[0058] Advantageously, the area density of wet-laid nonwoven materials allows for the manufacture of upstream elements that have required functional properties, such as the required pressure drop, for example, the pressure drop necessary to ensure proper aerosol delivery.

[0059] The wet-laid nonwoven material may be a sheet. The sheet may have a bobbin width of at least 400 mm. The sheet may have a bobbin width of up to 500 mm. The sheet may have a bobbin width of 400 mm to 500 mm.

[0060] The sheet may have a bobbin width of at least 120 mm. The sheet may have a bobbin width of up to 210 mm. The sheet may have a bobbin width of 120 mm to 210 mm.

[0061] Advantageously, the bobbin width is selected to ensure the manufacture of upstream elements that have the required functional characteristics, such as the required pressure drop, for example, the pressure drop necessary to ensure proper aerosol delivery.

[0062] Airlaid nonwoven materials or wet-laid nonwoven materials may be crimped nonwoven materials.

[0063] Advantageously, crimping airlaid or wetlaid nonwovens improves the manufacturability of upstream elements. Specifically, crimped nonwovens prevent expansion of upstream elements, which can break plug seals and / or damage consumable wrapping. Crimped nonwovens can also ensure that upstream elements have the required particle filtration properties, for example, that they do not contain airtight areas and / or areas with large holes.

[0064] The upstream element may have particle-retaining features.

[0065] Advantageously, the particle-retaining features of the upstream element help ensure that the particles are retained within the aerosol-generating article.

[0066] The particle-holding features may include multiple folds along the long axis.

[0067] The crimped nonwoven material may contain folds along its long axis. The crimped nonwoven material may contain multiple folds along its long axis. Each fold along its long axis may be spaced a certain distance apart from its adjacent folds along its long axis.

[0068] The distance between adjacent folds along the long axis may be less than 1000 micrometers. The distance between adjacent folds along the long axis may be less than 750 micrometers. The distance between adjacent folds along the long axis may be less than 500 micrometers.

[0069] The distance between adjacent folds along the long axis may be at least 25 micrometers. The distance between adjacent folds along the long axis may be at least 50 micrometers. The distance between adjacent folds along the long axis may be at least 100 micrometers.

[0070] The distance between adjacent folds along the long axis may be 25 micrometers to 1000 micrometers. The distance between adjacent folds along the long axis may be 25 micrometers to 750 micrometers. The distance between adjacent folds along the long axis may be 25 micrometers to 500 micrometers.

[0071] The distance between adjacent folds along the long axis may be 50 micrometers to 1000 micrometers. The distance between adjacent folds along the long axis may be 50 micrometers to 750 micrometers. The distance between adjacent folds along the long axis may be 50 micrometers to 500 micrometers.

[0072] The distance between adjacent folds along the long axis may be 100 micrometers to 1000 micrometers. The distance between adjacent folds along the long axis may be 100 micrometers to 750 micrometers. The distance between adjacent folds along the long axis may be 100 micrometers to 500 micrometers.

[0073] The distance between adjacent folds along the long axis may be smaller than the particle size of the aerosol-generating material particles.

[0074] Conveniently, the distance between adjacent folds along the long axis is optimized to ensure that the particle retention properties of the upstream element are appropriate.

[0075] A fold along the long axis, or each fold along the long axis, may have a height. The height of a fold along the long axis, or the height of each fold along the long axis, may correspond to the distance between adjacent folds along the long axis.

[0076] The height of the fold along the long axis, or the height of each fold along the long axis, may be less than 1000 micrometers. The height of the fold along the long axis, or the height of each fold along the long axis, may be less than 750 micrometers. The height of the fold along the long axis, or the height of each fold along the long axis, may be less than 500 micrometers.

[0077] The height of the fold along the long axis, or the height of each fold along the long axis, may be at least 25 micrometers. The height of the fold along the long axis, or the height of each fold along the long axis, may be at least 50 micrometers. The height of the fold along the long axis, or the height of each fold along the long axis, may be at least 100 micrometers.

[0078] The height of the fold along the long axis, or the height of each fold along the long axis, may be between 25 micrometers and 1000 micrometers. The height of the fold along the long axis, or the height of each fold along the long axis, may be between 25 micrometers and 750 micrometers. The height of the fold along the long axis, or the height of each fold along the long axis, may be between 25 micrometers and 500 micrometers.

[0079] The height of the fold along the long axis, or the height of each fold along the long axis, may be between 50 micrometers and 1000 micrometers. The height of the fold along the long axis, or the height of each fold along the long axis, may be between 50 micrometers and 750 micrometers. The height of the fold along the long axis, or the height of each adjacent fold along the long axis, may be between 50 micrometers and 500 micrometers.

[0080] The height of the fold along the long axis, or the height of each fold along the long axis, may be between 100 micrometers and 1000 micrometers. The height of the fold along the long axis, or the height of each fold along the long axis, may be between 100 micrometers and 750 micrometers. The height of the fold along the long axis, or the height of each fold along the long axis, may be between 100 micrometers and 500 micrometers.

[0081] The height of the folds along the long axis, or the height of each fold along the long axis, may be smaller than the particle size of the aerosol-generating material particles.

[0082] Conveniently, the height of the folds along the long axis, or the height of each fold along the long axis, is optimized to ensure that the particle retention properties of the upstream element are appropriate.

[0083] The upstream element may have a length of 5 millimeters.

[0084] The upstream element may have a draw resistance of 1.53 mm H2O per millimeter of the length of the upstream element.

[0085] The upstream element may have a draw resistance of 7.65 mmH2O.

[0086] Airlaid nonwoven materials or wet-laid nonwoven materials may have a bulk density of about 0.13 milligrams per cubic millimeter inside the upstream element.

[0087] The upstream elements may be heat-resistant.

[0088] The upstream elements may be resistant to shrinkage.

[0089] According to another aspect of the present invention, an upstream element for an aerosol-generating article is provided. The upstream element may include a nonwoven material.

[0090] The nonwoven material may be formed by an air-weave process. The upstream element may be formed by an air-forming process.

[0091] The nonwoven material may be formed by a wet-ray process. The upstream element may also be formed by a wet-ray process.

[0092] According to another aspect of the present invention, an upstream element for an aerosol-generating article is provided, the upstream element comprising a nonwoven material, and the nonwoven material being formed by an air array process.

[0093] Advantageously, the formation of upstream elements from airlaid nonwoven materials allows for the production of more sustainable upstream elements from, for example, natural or biodegradable materials, without compromising the functional and mechanical properties of the upstream elements.

[0094] According to another aspect of the present invention, an upstream element for an aerosol-generating article is provided, the upstream element comprising a nonwoven material, and the nonwoven material being formed by a wet lay process.

[0095] Airlaid nonwoven materials or wet-laid nonwoven materials may include fiber web materials. The fiber webs may be bonded by a high-pressure bonding process. The fiber webs may be bonded by a hydro-entanglement bonding process.

[0096] An airlaid nonwoven material or a wet-laid nonwoven material may be laid between a first roller and a second roller. The first roller may have at least one external ridge. The second roller may have at least one external groove. The at least one external ridge and the at least one external groove may be complementary. A corrugated pattern may be formed on the airlaid nonwoven material.

[0097] The airlaid nonwoven material or wet-laid nonwoven material may be pulled in a certain direction. The airlaid nonwoven material or wet-laid nonwoven material may be pulled in a certain direction between a first roller and a second roller. The corrugated pattern may be aligned with the direction in which the airlaid nonwoven material or wet-laid nonwoven material is pulled. The corrugated pattern may be a corrugated pattern in the longitudinal direction. The corrugated pattern may include multiple folds in the longitudinal direction. Each fold in the longitudinal direction may be spaced a certain distance from its adjacent folds in the longitudinal direction.

[0098] The distance between adjacent folds along the long axis may be less than 1000 micrometers. The distance between adjacent folds along the long axis may be less than 750 micrometers. The distance between adjacent folds along the long axis may be less than 500 micrometers.

[0099] The distance between adjacent folds along the long axis may be at least 25 micrometers. The distance between adjacent folds along the long axis may be at least 50 micrometers. The distance between adjacent folds along the long axis may be at least 100 micrometers.

[0100] The distance between adjacent folds along the long axis may be 25 micrometers to 1000 micrometers. The distance between adjacent folds along the long axis may be 25 micrometers to 750 micrometers. The distance between adjacent folds along the long axis may be 25 micrometers to 500 micrometers.

[0101] The distance between adjacent folds along the long axis may be 50 micrometers to 1000 micrometers. The distance between adjacent folds along the long axis may be 50 micrometers to 750 micrometers. The distance between adjacent folds along the long axis may be 50 micrometers to 500 micrometers.

[0102] The distance between adjacent folds along the long axis may be 100 micrometers to 1000 micrometers. The distance between adjacent folds along the long axis may be 100 micrometers to 750 micrometers. The distance between adjacent folds along the long axis may be 100 micrometers to 500 micrometers.

[0103] A fold along the long axis, or each fold along the long axis, may have a height. The height of a fold along the long axis, or the height of each fold along the long axis, may correspond to the distance between adjacent folds along the long axis.

[0104] The height of the fold along the long axis, or the height of each fold along the long axis, may be less than 1000 micrometers. The height of the fold along the long axis, or the height of each fold along the long axis, may be less than 750 micrometers. The height of the fold along the long axis, or the height of each fold along the long axis, may be less than 500 micrometers.

[0105] The height of the fold along the long axis, or the height of each fold along the long axis, may be at least 25 micrometers. The height of the fold along the long axis, or the height of each fold along the long axis, may be at least 50 micrometers. The height of the fold along the long axis, or the height of each fold along the long axis, may be at least 100 micrometers.

[0106] The height of the fold along the long axis, or the height of each fold along the long axis, may be between 25 micrometers and 1000 micrometers. The height of the fold along the long axis, or the height of each fold along the long axis, may be between 25 micrometers and 750 micrometers. The height of the fold along the long axis, or the height of each fold along the long axis, may be between 25 micrometers and 500 micrometers.

[0107] The height of the fold along the long axis, or the height of each fold along the long axis, may be between 50 micrometers and 1000 micrometers. The height of the fold along the long axis, or the height of each fold along the long axis, may be between 50 micrometers and 750 micrometers. The height of the fold along the long axis, or the height of each adjacent fold along the long axis, may be between 50 micrometers and 500 micrometers.

[0108] The height of the fold along the long axis, or the height of each fold along the long axis, may be between 100 micrometers and 1000 micrometers. The height of the fold along the long axis, or the height of each fold along the long axis, may be between 100 micrometers and 750 micrometers. The height of the fold along the long axis, or the height of each fold along the long axis, may be between 100 micrometers and 500 micrometers.

[0109] The airlaid nonwoven material or wet-laid nonwoven material may be subjected to one or more further processes. One or more further processes may control the distance between adjacent longitudinal folds. One or more further processes may include an embossing process. The corrugated airlaid nonwoven material or corrugated wet-laid nonwoven material may be drawn through a funnel device. The corrugated airlaid nonwoven material or corrugated wet-laid nonwoven material may be drawn through a funnel device to form a cylinder. The cylinder may be rolled. The cylinder may be cut into one or more plugs.

[0110] The upstream element may be a plug. The upstream element may be a forward plug.

[0111] According to another aspect of the present invention, a method for manufacturing an upstream element is provided. The method may include air-laiding a sheet of nonwoven material. The method may include forming a cylinder of air-laid nonwoven material. The method may include winding the cylinder. The method may include cutting the cylinder into one or more plugs.

[0112] According to another aspect of the present invention, a method for manufacturing an upstream element is provided, the method comprising air-laiding a sheet of nonwoven material, forming a cylinder of air-laid nonwoven material, winding the cylinder, and cutting the cylinder into one or more plugs.

[0113] Advantageously, the production of upstream elements from airlaid nonwoven materials allows for the use of more sustainable materials, such as natural or biodegradable materials, without compromising the functional and mechanical properties of the upstream elements.

[0114] The method may include crimping the airlaid nonwoven material. The method may also include embossing the airlaid nonwoven material.

[0115] According to another aspect of the present invention, a method for manufacturing an upstream element is provided. The method may include wet laying a sheet of nonwoven material. The method may include forming a cylinder of the wet-laid nonwoven material. The method may include winding the cylinder. The method may include cutting the cylinder into one or more plugs.

[0116] According to another aspect of the present invention, a method for manufacturing an upstream element is provided, the method comprising wet-laying a sheet of nonwoven material, forming a cylinder of the wet-laid nonwoven material, winding the cylinder, and cutting the cylinder into one or more plugs.

[0117] Advantageously, the production of upstream elements from wet-laid nonwoven materials allows for the use of more sustainable materials, such as natural or biodegradable materials, without compromising the functional and mechanical properties of the upstream elements.

[0118] The method may include crimping the wet-laid nonwoven material. The method may also include embossing the wet-laid nonwoven material.

[0119] According to another aspect of the present invention, there is an aerosol generating article comprising an aerosol generating substrate. The aerosol generating article may include an upstream element. The upstream element may be an upstream element according to a prior aspect of the present invention. The upstream element may be located upstream of the aerosol generating substrate. The upstream element may be the upstreammost plug of the aerosol generating article.

[0120] The aerosol-generating article may include a downstream element. The downstream element may include one or more ventilation holes. One or more ventilation holes may be arranged around the periphery of the downstream element. One or more ventilation holes may be arranged around the periphery of the downstream element.

[0121] The aerosol-generating article may be equipped with a mouthpiece filter.

[0122] The aerosol generator may include an aerosol generating article. The aerosol generating article may be an aerosol generating article as described in a prior embodiment of the present invention. The aerosol generator may be configured to heat the aerosol generating substrate of the aerosol generating article. The aerosol generator may include a housing. The housing may define a cavity. The cavity may be configured to receive the aerosol generating article.

[0123] This invention offers several advantages over the upstream elements of the prior art.

[0124] The formation of upstream elements from airlaid or wet-laid nonwoven materials, such as biodegradable materials, including cellulose, enables the inexpensive and straightforward production of more sustainable upstream elements.

[0125] Using airlaid or wet-laid nonwoven materials with optimized area density ensures that the pressure drop level required to achieve adequate aerosol delivery is obtained.

[0126] Crimping airlaid or wet-laid nonwovens improves the manufacturability of upstream elements. Specifically, crimped airlaid or wet-laid nonwovens prevent undesirable expansion of upstream elements and thus reduce the risk of breaking plug seals or damaging wound consumables. Crimped airlaid or wet-laid nonwovens also help maintain the desired particle filtration properties of upstream elements by preventing the formation of airtight areas or large holes in the upstream elements. The crimping process creates a "wave-like" structure within the airlaid or wet-laid nonwoven, breaking the fibers of the airlaid or wet-laid nonwoven, so that when compressed in a funnel device, the airlaid or wet-laid nonwoven collapses in random directions, so that different layers / segments of the airlaid or wet-laid nonwoven cannot adhere to each other and also prevent the formation of unexpected large holes. As a result, the crimping process is advantageous in that it allows for the creation of upstream elements of airlaid or wet-laid nonwoven materials that effectively block particles of aerosol-generating material and have expected and desirable draw resistance.

[0127] A further advantage of the upsteam element of the present invention is that the crimped airlaid or wetlaid nonwoven upstream element has higher temperature resistance than cellulose acetate. Therefore, visually and aesthetically, the crimped airlaid nonwoven upstream element remains intact after heating of the consumable (i.e., after user experience). Temperature resistance is also important in terms of draw resistance. The draw resistance of the upstream element remains unchanged throughout the experience, thus preserving the quality, characteristics, and dimensions of the crimped airlaid or wetlaid nonwoven upstream element. As a result, the fact that the diameter of the crimped airlaid or wetlaid nonwoven upstream element does not change means it can serve a dual purpose as a cleaning tool for the inner walls of the heating cavity of the aerosol generator. After the experience is complete, some droplets may accumulate on the inner wall of the consumable heating cavity, which is advantageous as it is where the uncorrected outer diameter of the crimped airlaid or wet-laid nonwoven upstream element "scrapes" against the inner wall of the heating cavity, and in doing so cleans it from any dirt / outside elements that may have accidentally entered the heating chamber.

[0128] The hardness achieved for the airlaid or wetlaid nonwoven upstream element of the present invention is comparable to, if not higher than, the hardness of conventional upstream elements. Increasing the hardness of the upstream element improves stick insertion.

[0129] 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 or aerosol generating article with respect to the direction in which the user inhales the aerosol generator or aerosol generating article during its use.

[0130] The aerosol generator may have a mouth end through which, during use, 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, and particularly preferably, the user may inhale directly an aerosol generating article inserted into an opening at the proximal end of the aerosol generator. In this case, the user preferably inhales the front plug of the aerosol generating article. The opening at the proximal end of the aerosol generator may be a cavity opening. The cavity may be configured to receive an aerosol generating article. The 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 or parts of an aerosol generator may be described as being upstream or downstream of each other based on their relative positions between the proximal end, downstream end, or mouth end of the aerosol generator and the distal end or upstream end of the aerosol generator.

[0131] 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.

[0132] 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.

[0133] 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, 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, control the supply of power to the heating element in accordance with the electrical resistance of the heating element.

[0134] An 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, 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 sufficient capacity to continuously generate aerosols for a period of approximately 6 minutes, or a period of multiples of 6 minutes. In another embodiment, the power source may have sufficient capacity to provide a predetermined number of fume extractions or discontinuous activation of the heating element.

[0135] 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.

[0136] 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.

[0137] 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.

[0138] 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.

[0139] 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, and then sandwiched between other insulating materials such as glass. The heater thus formed may be used both for heating a heating element in operation and for monitoring its temperature.

[0140] 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, a flexible printed circuit board, a molded circuit component (MID), a ceramic heater, a flexible carbon fiber heater, or may 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 both for heating the external heating element and for monitoring its temperature during operation.

[0141] 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, typically, eddy currents are induced by the alternating magnetic field. If the susceptor is magnetic, typically, another effect that contributes to heating is generally called hysteresis loss. Hysteresis loss arises primarily from the movement of magnetic domain blocks within the susceptor, because their magnetic orientations align with the alternating induced 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 or 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.

[0142] 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. An aerosol-generating article may be disposable.

[0143] As used herein, the term “aerosol-forming substrate” refers to a substrate having the ability to release one or more volatile compounds that can form 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.

[0144] 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 include glycerin and propylene glycol.

[0145] The aerosol generating substrate preferably comprises homogenized tobacco material, an aerosol forming agent, and water. Most preferably, the aerosol generating substrate contains glycerin as a cut filler and an aerosol forming agent. 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.

[0146] Where used herein in relation to this disclosure, the term “longitudinal direction” is used to describe the direction between the upstream and downstream ends of an aerosol-generating article. During use, air is drawn through the aerosol-generating article in the longitudinal direction.

[0147] Where used herein in relation to this disclosure, the term "length" is used to describe the maximum dimension in the longitudinal direction of an aerosol-generating article or a component of an aerosol-generating article.

[0148] Where used herein in connection with this disclosure, the term “transverse direction” is used to describe a direction perpendicular to the longitudinal axis. Unless otherwise stated, a “cross section” of an aerosol-generating article or a component of an aerosol-generating article refers to a cross section.

[0149] Where used herein in relation to this disclosure, the term “width” refers to the maximum transverse dimension of an aerosol-generating article or a component of an aerosol-generating article. If the aerosol-generating article has a substantially circular cross-section, the width of the aerosol-generating article corresponds to the diameter of the aerosol-generating article. If the components of the aerosol-generating article have a substantially circular cross-section, the width of the components of the aerosol-generating article corresponds to the diameter of the components of the aerosol-generating article.

[0150] Unless otherwise specified, the draw-to-discharge (RTD) of an aerosol-generating article or its components is measured in accordance with ISO 6565-2015 at a temperature of approximately 22 degrees Celsius, a pressure of approximately 101 kPa (approximately 760 Torr), and a relative humidity of approximately 60%, at a volumetric flow rate of approximately 17.5 milliliters per second at the proximal end, i.e., the downstream end, of the aerosol-generating article or its components.

[0151] The present invention is defined in the claims. However, 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 any of the features described above, for example, one or more features of other embodiments, forms, or aspects described herein. [Brief explanation of the drawing]

[0152] [Figure 1] Figure 1 is a schematic diagram of an aerosol generating article including an upstream element according to the present invention. [Figure 2] Figure 2 is a flowchart showing the steps of the air array process. [Figure 3] Figure 3 is a schematic diagram of a crimping roller. [Figure 4] Figure 4 is a flowchart showing the steps in the crimping process. [Modes for carrying out the invention]

[0153] Example Ex1: Upstream element for an aerosol generating article, the upstream element being formed of a nonwoven material.

[0154] Example Ex2: An upstream element according to Example EX1, wherein the upstream element is formed of an airlaid nonwoven material.

[0155] Example Ex3: An upstream element according to Example Ex1, wherein the nonwoven material is a wet-laid nonwoven material.

[0156] Example Ex4: Upstream element according to Example Ex2 or Ex3, wherein the airlaid nonwoven material or wet-laid nonwoven material includes a biodegradable material.

[0157] Example Ex5: An upstream element comprising one of Ex2, Ex3, or Ex4, wherein the airlaid nonwoven material or wet-laid nonwoven material contains cellulose fibers.

[0158] Example Ex6: An upstream element according to any one of Examples Ex2 to Ex5, wherein the airlaid nonwoven material or wet-laid nonwoven material contains at least 90 weight percent cellulose.

[0159] Example Ex7: An upstream element according to any of Examples Ex2 to Ex6, wherein the airlaid nonwoven material or wet-laid nonwoven material contains at least 95% by weight of cellulose.

[0160] Example Ex8: An upstream element according to any of Examples Ex2 to Ex7, wherein the airlaid nonwoven material or wet-laid nonwoven material contains at least 99% by weight of cellulose.

[0161] Example Ex9: An upstream element according to any of Examples Ex2 to Ex8, wherein the airlaid nonwoven material or wet-laid nonwoven material contains 100% by weight cellulose.

[0162] Example Ex10: An upstream element according to any of Examples Ex2 to Ex9, comprising an airlaid nonwoven material or a wet-laid nonwoven material, including a fiber web material.

[0163] Example Ex11: Upstream element according to Example Ex10, comprising a bonded web of airlaid nonwoven material or wet-laid nonwoven material.

[0164] Example Ex12: The upstream element described in Example Ex11, wherein the bonded web is a high-pressure bonded web.

[0165] Example Ex13: The upstream element according to Example Ex11 or Ex12, wherein the bonded web is a hydroentangled web.

[0166] Example Ex14: An upstream element according to any of Examples Ex2 to Ex13, wherein the airlaid nonwoven material or wet-laid nonwoven material has a weight of at least 15 grams per square meter of surface area.

[0167] Example Ex15: An upstream element according to any of Examples Ex2 to Ex14, wherein the airlaid nonwoven material or wet-laid nonwoven material has a weight of at least 30 grams per square meter of surface area.

[0168] Example Ex16: An upstream element according to any of Examples Ex2 to Ex15, wherein the airlaid nonwoven material or wet-laid nonwoven material has a weight of at least 50 grams per square meter of surface area.

[0169] Example Ex17: An upstream element according to any of Examples Ex2 to Ex16, wherein the airlaid nonwoven material or wet-laid nonwoven material has a weight of at least 60 grams per square meter of surface area.

[0170] Example Ex18: An upstream element according to any of Examples Ex2 to Ex17, wherein the airlaid nonwoven material or wet-laid nonwoven material has a maximum weight of 600 grams per square meter of surface area.

[0171] Example Ex19: An upstream element according to any of Examples Ex2 to Ex18, wherein the airlaid nonwoven material or wet-laid nonwoven material has a maximum weight of 200 grams per square meter of surface area.

[0172] Example Ex20: An upstream element according to any of Examples Ex2 to Ex19, wherein the airlaid nonwoven material or wet-laid nonwoven material has a maximum weight of 70 grams per square meter per surface area.

[0173] Example Ex21: An upstream element according to any of Examples Ex2 to Ex13, wherein the airlaid nonwoven material or wet-laid nonwoven material has a weight per square meter of surface area ranging from 15 grams per square meter to 600 grams per square meter.

[0174] Example Ex22: An upstream element according to any of Examples Ex2 to Ex13, wherein the airlaid nonwoven material or wet-laid nonwoven material has a weight per square meter of surface area ranging from 30 grams per square meter to 200 grams per square meter.

[0175] Example Ex23: An upstream element according to any of Examples Ex2 to Ex13, wherein the airlaid nonwoven material or wet-laid nonwoven material has a weight per surface area of ​​60 grams per square meter to 180 grams per square meter.

[0176] Example Ex24: An upstream element according to any of Examples Ex2 to Ex13, wherein the airlaid nonwoven material or wet-laid nonwoven material has a weight of 62 grams per square meter per surface area.

[0177] Example Ex25: An upstream element according to any of Examples Ex2 to Ex13, wherein the airlaid nonwoven material or wet-laid nonwoven material has a weight of 170 grams per square meter per surface area.

[0178] Example Ex26: An upstream element according to any of Examples Ex2 to Ex25, wherein the airlaid nonwoven material or wet-laid nonwoven material is a sheet.

[0179] Example Ex27: Upstream element according to Example Ex26, wherein the sheet has a bobbin width of at least 400 mm.

[0180] Example Ex28: Upstream element according to Example Ex26 or Ex27, where the sheet has a bobbin width of up to 500 mm.

[0181] Example Ex29: Upstream element according to Example Ex26, where the sheet has a bobbin width of 400 mm to 500 mm.

[0182] Example Ex30: Upstream element according to Example Ex26, wherein the sheet has a bobbin width of at least 120 mm.

[0183] Example Ex31: Upstream element according to Example Ex26 or Ex30, with a sheet having a bobbin width of up to 210 mm.

[0184] Example Ex32: Upstream element according to Example Ex26, where the sheet has a bobbin width of 120 mm to 210 mm.

[0185] Example Ex33: An upstream element according to any of Examples Ex2 to Ex32, wherein the airlaid nonwoven material or wet-laid nonwoven material is a crimped nonwoven material.

[0186] Example Ex34: An upstream element according to any of Examples Ex2 to Ex33, wherein the upstream element has particle-holding characteristics.

[0187] Example Ex35: An upstream element according to any of Examples Ex2 to Ex34, in which a crimped nonwoven material includes folds in the longitudinal direction.

[0188] Example Ex36: An upstream element according to Example Ex35, in which a crimped nonwoven material includes multiple folds along the long axis.

[0189] Example Ex37: An upstream element according to Example Ex36, in which each fold in the longitudinal direction is separated by a certain distance from the adjacent fold in the longitudinal direction.

[0190] Example Ex38: Upstream element according to Example Ex37, where the distance between adjacent longitudinal folds is less than 1000 micrometers.

[0191] Example Ex39: An upstream element according to Example 37 or Ex38, wherein the distance between adjacent longitudinal folds is less than 750 micrometers.

[0192] Example Ex40: Upstream element according to Example Ex37, Ex38, or Ex39, wherein the distance between adjacent longitudinal folds is less than 500 micrometers.

[0193] Example Ex41: An upstream element according to any of Examples Ex37 to Ex40, wherein the distance between adjacent longitudinal folds is at least 25 micrometers.

[0194] Example Ex42: An upstream element according to any of Examples Ex37 to Ex41, wherein the distance between adjacent longitudinal folds is at least 50 micrometers.

[0195] Example Ex43: An upstream element according to any of Examples Ex37 to Ex42, wherein the distance between adjacent longitudinal folds is at least 100 micrometers.

[0196] Example Ex44: Upstream element according to Example Ex37, where the distance between adjacent longitudinal folds is 25 micrometers to 1000 micrometers.

[0197] Example Ex45: An upstream element according to Example Ex44, wherein the distance between adjacent longitudinal folds is 25 micrometers to 750 micrometers.

[0198] Example Ex46: Upstream element according to Example Ex44 or Ex45, wherein the distance between adjacent longitudinal folds is 25 micrometers to 500 micrometers.

[0199] Example Ex47: An upstream element according to Example Ex37, wherein the distance between adjacent longitudinal folds is 50 micrometers to 1000 micrometers.

[0200] Example Ex48: Upstream element according to Example Ex47, wherein the distance between adjacent longitudinal folds is 50 micrometers to 750 micrometers.

[0201] Example Ex49: Upstream element according to Example Ex47 or Ex48, wherein the distance between adjacent longitudinal folds is 50 micrometers to 500 micrometers.

[0202] Example Ex50: Upstream element according to Example Ex37, where the distance between adjacent longitudinal folds is 100 micrometers to 1000 micrometers.

[0203] Example Ex51: Upstream element according to Example Ex50, where the distance between adjacent longitudinal folds is 100 micrometers to 750 micrometers.

[0204] Example Ex52: An upstream element according to Example Ex50 or Ex51, wherein the distance between adjacent longitudinal folds is 100 micrometers to 500 micrometers.

[0205] Example Ex53: An upstream element according to any of Examples Ex37 to Ex52, wherein the folds in the longitudinal direction, or each fold in the longitudinal direction, have height, and the height of the folds in the longitudinal direction, or each fold in the longitudinal direction, corresponds to the distance between adjacent folds in the longitudinal direction.

[0206] Example Ex54: An upstream element according to Example Ex53, wherein the folds in the longitudinal direction, or the height of each fold in the longitudinal direction, are less than 1000 micrometers.

[0207] Example Ex55: An upstream element according to Example Ex53 or Ex54, wherein the folds in the longitudinal direction, or the height of each fold in the longitudinal direction, is less than 750 micrometers.

[0208] Example Ex56: An upstream element according to Example Ex53, Ex54, or Ex55, wherein the folds in the longitudinal direction, or the height of each fold in the longitudinal direction, is less than 500 micrometers.

[0209] Example Ex57: An upstream element according to any of Examples Ex53 to Ex56, wherein the folds in the longitudinal direction, or the height of each fold in the longitudinal direction, is at least 25 micrometers.

[0210] Example Ex58: An upstream element according to any of Examples Ex53 to Ex57, wherein the folds in the longitudinal direction, or the height of each fold in the longitudinal direction, is at least 50 micrometers.

[0211] Example Ex59: An upstream element according to any of Examples Ex53 to Ex58, wherein the folds in the longitudinal direction, or the height of each fold in the longitudinal direction, is at least 100 micrometers.

[0212] Example Ex60: An upstream element according to Example Ex53, wherein the folds in the longitudinal direction, or the height of each fold in the longitudinal direction, are 25 micrometers to 1000 micrometers.

[0213] Example Ex61: An upstream element according to Example Ex60, wherein the folds in the longitudinal direction, or the height of each fold in the longitudinal direction, are 25 micrometers to 750 micrometers.

[0214] Example Ex62: An upstream element according to Example Ex60 or Ex61, wherein the folds in the longitudinal direction, or the height of each fold in the longitudinal direction, are 25 micrometers to 500 micrometers.

[0215] Example Ex63: An upstream element according to Example Ex53, wherein the folds in the longitudinal direction, or the height of each fold in the longitudinal direction, are 50 micrometers to 1000 micrometers.

[0216] Example Ex64: An upstream element according to Example Ex63, wherein the folds in the longitudinal direction, or the height of each fold in the longitudinal direction, are 50 micrometers to 750 micrometers.

[0217] Example Ex65: An upstream element according to Example Ex63 or Ex64, wherein the height of adjacent longitudinal folds, or each adjacent longitudinal fold, is between 50 micrometers and 500 micrometers.

[0218] Example Ex66: An upstream element according to Example Ex53, wherein the folds along the long axis, or the height of each fold along the long axis, is 100 micrometers to 1000 micrometers.

[0219] Example Ex67: An upstream element according to Example Ex66, wherein the folds along the long axis, or the height of each fold along the long axis, is between 100 micrometers and 750 micrometers.

[0220] Example Ex68: An upstream element according to Example Ex66 or Ex67, wherein the folds in the longitudinal direction, or the height of each fold in the longitudinal direction, are 100 to 500 micrometers.

[0221] Example Ex69: An upstream element according to any of Examples Ex2 to Ex68, having a length of 5 millimeters.

[0222] Example Ex70: Upstream element according to Example Ex69, wherein the upstream element has an H2O draw resistance of 1.53 mm per millimeter of length of the upstream element.

[0223] Example Ex71: Upstream element according to Example Ex69 or Ex70, wherein the upstream element has a draw resistance of 7.65 mmH2O.

[0224] Example Ex72: An upstream element according to any of Examples Ex2 to Ex71, wherein the airlaid nonwoven material or wet-laid nonwoven material has an internal bulk density of about 0.13 milligrams per cubic millimeter.

[0225] Example Ex73: An upstream element according to any of Examples Ex2 to Ex71, wherein the upstream element is heat resistant.

[0226] Example Ex74: An upstream element according to any of Examples Ex2 to Ex73, wherein the upstream element is resistant to shrinkage.

[0227] Example Ex75: An upstream element for an aerosol-generating article, comprising a nonwoven material, wherein the nonwoven material is formed by an air-ray process or air-forming process or a wet-ray process or wet-forming process.

[0228] Example Ex76: An upstream element according to Example Ex75, wherein the airlaid nonwoven material or wet-laid nonwoven material comprises a fiber web material, and the fiber web is bonded by a high-pressure bonding process.

[0229] Example Ex77: Upstream elements according to Example Ex76, where a fiber web is bonded by a hydro-entanglement bonding process.

[0230] Example Ex78: An upstream element according to Examples Ex75, Ex76, or Ex77, wherein an airlaid nonwoven material or a wet-laid nonwoven material is pulled between a first roller having at least one external ridge and a second roller having at least one external groove, wherein the at least one external ridge and the at least one external groove are complementary, thereby forming a corrugated pattern on the airlaid nonwoven material.

[0231] Example Ex79: An upstream element according to Example Ex78, wherein an airlaid nonwoven material or a wet-laid nonwoven material is pulled in a certain direction between a first roller and a second roller, and the corrugated pattern is aligned with the direction in which the airlaid nonwoven material or wet-laid nonwoven material is pulled.

[0232] Example Ex80: An upstream element according to Example Ex78 or Ex79, wherein the waveform pattern is a waveform pattern in the long axis direction.

[0233] Example Ex81: An upstream element according to claim Ex78, Ex79, or Ex80, wherein the waveform pattern includes a plurality of folds along the long axis.

[0234] Example Ex82: An upstream element according to Example Ex81, in which each fold in the longitudinal direction is separated by a certain distance from the adjacent fold in the longitudinal direction.

[0235] Example Ex83: Upstream element according to Example Ex82, wherein the distance between adjacent longitudinal folds is less than 1000 micrometers.

[0236] Example Ex84: An upstream element according to Example 82 or Ex83, wherein the distance between adjacent longitudinal folds is less than 750 micrometers.

[0237] Example Ex85: An upstream element according to Example Ex82, Ex83, or Ex84, wherein the distance between adjacent longitudinal folds is less than 500 micrometers.

[0238] Example Ex86: An upstream element according to any of Examples Ex82 to Ex85, wherein the distance between adjacent longitudinal folds is at least 25 micrometers.

[0239] Example Ex87: An upstream element according to any of Examples Ex82 to Ex86, wherein the distance between adjacent longitudinal folds is at least 50 micrometers.

[0240] Example Ex88: An upstream element according to any of Examples Ex82 to Ex87, wherein the distance between adjacent longitudinal folds is at least 100 micrometers.

[0241] Example Ex89: Upstream element according to Example Ex82, where the distance between adjacent longitudinal folds is 25 micrometers to 1000 micrometers.

[0242] Example Ex90: Upstream element according to Example Ex89, where the distance between adjacent longitudinal folds is 25 micrometers to 750 micrometers.

[0243] Example Ex91: An upstream element according to Example Ex89 or Ex89, wherein the distance between adjacent longitudinal folds is 25 micrometers to 500 micrometers.

[0244] Example Ex92: An upstream element according to Example Ex82, wherein the distance between adjacent longitudinal folds is 50 micrometers to 1000 micrometers.

[0245] Example Ex93: Upstream element according to Example Ex92, wherein the distance between adjacent longitudinal folds is 50 micrometers to 750 micrometers.

[0246] Example Ex94: An upstream element according to Example Ex92 or Ex93, wherein the distance between adjacent longitudinal folds is 50 micrometers to 500 micrometers.

[0247] Example Ex95: Upstream element according to Example Ex82, where the distance between adjacent longitudinal folds is 100 micrometers to 1000 micrometers.

[0248] Example Ex96: Upstream element according to Example Ex95, wherein the distance between adjacent longitudinal folds is 100 micrometers to 750 micrometers.

[0249] Example Ex97: An upstream element according to Example Ex95 or Ex96, wherein the distance between adjacent longitudinal folds is 100 micrometers to 500 micrometers.

[0250] Example Ex98: An upstream element according to Example Ex82, wherein the folds in the longitudinal direction, or each fold in the longitudinal direction, have height, and the height of the folds in the longitudinal direction, or each fold in the longitudinal direction, corresponds to the distance between adjacent folds in the longitudinal direction.

[0251] Example Ex99: An upstream element according to Example Ex98, wherein the folds in the longitudinal direction, or the height of each fold in the longitudinal direction, are less than 1000 micrometers.

[0252] Example Ex100: An upstream element according to Example Ex98 or Ex99, wherein the folds in the longitudinal direction, or the height of each fold in the longitudinal direction, are less than 750 micrometers.

[0253] Example Ex101: An upstream element according to Example Ex98, Ex99, or Ex100, wherein the folds in the longitudinal direction, or the height of each fold in the longitudinal direction, are less than 500 micrometers.

[0254] Example Ex102: An upstream element according to any of Examples Ex98 to Ex101, wherein the folds in the longitudinal direction, or the height of each fold in the longitudinal direction, is at least 25 micrometers.

[0255] Example Ex103: An upstream element according to any of Examples Ex98 to Ex102, wherein the folds in the longitudinal direction, or the height of each fold in the longitudinal direction, is at least 50 micrometers.

[0256] Example Ex104: An upstream element according to any of Examples Ex98 to Ex103, wherein the folds along the long axis, or the height of each fold along the long axis, is at least 100 micrometers.

[0257] Example Ex105: An upstream element according to Example Ex98, wherein the folds along the long axis, or the height of each fold along the long axis, is 25 micrometers to 1000 micrometers.

[0258] Example Ex106: An upstream element according to Example Ex105, wherein the folds in the longitudinal direction, or the height of each fold in the longitudinal direction, are between 25 micrometers and 750 micrometers.

[0259] Example Ex107: An upstream element according to Example Ex105 or Ex106, wherein the folds in the longitudinal direction, or the height of each fold in the longitudinal direction, are between 25 micrometers and 500 micrometers.

[0260] Example Ex108: An upstream element according to Example Ex98, wherein the folds along the long axis, or the height of each fold along the long axis, is 50 micrometers to 1000 micrometers.

[0261] Example Ex109: An upstream element according to Example Ex108, wherein the folds along the long axis, or the height of each fold along the long axis, is between 50 micrometers and 750 micrometers.

[0262] Example Ex110: An upstream element according to Example Ex108 or Ex109, wherein the height of adjacent longitudinal folds, or each adjacent longitudinal fold, is between 50 micrometers and 500 micrometers.

[0263] Example Ex111: An upstream element according to Example Ex98, wherein the folds along the long axis, or the height of each fold along the long axis, is 100 micrometers to 1000 micrometers.

[0264] Example Ex112: An upstream element according to Example Ex111, wherein the folds along the long axis, or the height of each fold along the long axis, is between 100 micrometers and 750 micrometers.

[0265] Example Ex113: An upstream element according to Example Ex111 or Ex112, wherein the folds along the long axis, or the height of each fold along the long axis, is 100 micrometers to 500 micrometers.

[0266] Example Ex114: An upstream element according to any of Examples Ex75 to Ex113, in which an airlaid nonwoven material is subjected to one or more further processes to control the distance between adjacent longitudinal folds.

[0267] Example Ex115: An upstream element according to Example Ex114, wherein one or more further processes include an embossing process.

[0268] Example Ex116: An upstream element according to Example Ex114 or Ex115, in which corrugated airlaid nonwoven material or corrugated wetlaid nonwoven material is drawn through a funnel device to form a cylinder.

[0269] Example Ex117: Upstream element according to Example Ex116, in which a cylinder is wound.

[0270] Example Ex118: An upstream element according to Example Ex116 or Ex117, in which a cylinder is cut into one or more plugs.

[0271] Example Ex119: Upstream element according to Example Ex118, where the upstream element is a plug.

[0272] Example Ex120: Upstream element according to Example Ex118 or Ex119, wherein the upstream element is a forward plug.

[0273] Example Ex121: A method for manufacturing an upstream element, comprising air-laiding a sheet of nonwoven material, forming a cylinder of air-laid nonwoven material, winding the cylinder, and cutting the cylinder into one or more plugs.

[0274] Example Ex122: The method according to Example Ex121, further comprising crimping an airlaid nonwoven material.

[0275] Example Ex123: The method according to Example Ex121 or Ex122, further comprising embossing an airlaid nonwoven material.

[0276] Example Ex124: A method for manufacturing an upstream element, comprising wet-laying a sheet of nonwoven material, forming a cylinder of the wet-laid nonwoven material, winding the cylinder, and cutting the cylinder into one or more plugs.

[0277] Example Ex125: The method according to Example Ex124, further comprising crimping a wet-laid nonwoven material.

[0278] Example Ex126: The method according to Example Ex124 or Ex125, further comprising embossing a wet-laid nonwoven material.

[0279] Example Ex127: An aerosol generating article comprising an aerosol generating substrate and an upstream element according to any of Examples EX1 to Ex120, wherein the upstream element is located upstream of the aerosol generating substrate.

[0280] Example Ex128: An aerosol generating article according to Example Ex127, wherein the upstream element is the upstream plug of the aerosol generating article.

[0281] Example Ex129: An aerosol-generating article according to Example Ex127 or Ex128, comprising a downstream element.

[0282] Example Ex130: An aerosol-generating article according to Example Ex129, wherein the downstream element has one or more ventilation holes.

[0283] Example Ex131: An aerosol-generating article according to Example Ex130, wherein one or more ventilation holes are arranged around the periphery of a downstream element.

[0284] Example Ex132: An aerosol-generating article according to Example Ex130 or Ex131, wherein one or more ventilation holes are arranged around the periphery of the downstream element.

[0285] Example Ex133: An aerosol-generating article according to any of Examples Ex127 to Ex132, comprising a mouthpiece filter.

[0286] Example Ex134: An aerosol generator according to any one of Examples Ex127 to Ex133, wherein the aerosol generator is configured to heat the aerosol generating substrate of the aerosol generating article.

[0287] Example Ex135: An aerosol generator according to Example Ex134, comprising a housing defining a cavity configured to receive an aerosol-generating article.

[0288] Here, we will further describe the examples with reference to the figures.

[0289] Referring to Figure 1, the aerosol generating article 10 has a cylindrical body having an upstream or distal end 12 and a downstream or proximal end 14. The aerosol generating article 10 is configured to be inserted into a tubular cavity of an electrically heated electron aerosol generator (not shown).

[0290] The downstream end 12 includes a mouthpiece filter 16, which is intended to remain outside the aerosol generator and is placed between the user's lips, and may include a filter.

[0291] The upstream end 14 is intended to be placed inside the aerosol generating device and includes a substrate portion 18 comprising an aerosol generating substrate containing an aerosol generating material such as a tobacco-containing material, and an upstream element in the form of a front plug 20. The front plug 20 protects the aerosol generating substrate within the substrate portion 18 from external conditions.

[0292] The aerosol generating article 10 may include another plug 22, for example, a plug that provides a cooling function and is located midway between the downstream end 12 and the upstream end 14.

[0293] The front plug 20 prevents by-products of the aerosol generating article 10 from entering the aerosol generating device. Such by-products include a liquid slurry made from a combination of water (from the humidity of the air) and the heated aerosol generating material, and particles of the aerosol generating material that may dry and become brittle after the heating cycle.

[0294] The front plug 20 of the present invention is formed from a non-woven material produced by an airlaid process 100 as described while referring to FIG. 2. In step 102, fibers of a material containing at least 90 percent cellulose are mixed with air. This results in the formation of a uniform air-fiber mixture. The uniform air-fiber mixture is deposited onto a moving breathable belt or wire (step 104) to form a web. In step 106, the web is bonded, for example, using latex, using a high-pressure bonding process such as hydroentanglement. The material is compressed such that the pulp fibers are interconnected within the "pressed" area. Advantageously, this results in a strong material without a reduction in gas permeability in areas not subjected to pressing. Therefore, the airlaid non-woven material from which the front plug 20 is made can be manufactured using a particularly inexpensive and efficient continuous process.

[0295] Here, the manufacture of the front plug 20 from the airlaid non-woven material will be described while referring to FIGS. 3 and 4.

[0296] Referring to FIG. 3 here, a sheet 30 of airlaid nonwoven material, a first crimping roller 32, a second crimping roller 34, and a crimped sheet 36 of airlaid nonwoven material are shown. The first crimping roller 32 and the second crimping roller 34 have complementary ridges and grooves (not shown) on their outer surfaces.

[0297] Referring to FIG. 4, in the first step 202 of the process 200, as the crimping rollers 32, 34 rotate, a continuous strip or sheet 30 of airlaid nonwoven fabric material is drawn through the first crimping roller 32 and the second crimping roller 34. This creates a wavy pattern on the crimped sheet 36.

[0298] As shown in FIG. 4, the crimping ridges are aligned with the direction of the moving strip of material, i.e., the crimping ridges are in the long axis direction.

[0299] In the second step 204, the wavy material 36 is drawn through a funnel-shaped device to form a compression rod.

[0300] The compression rod is then wound and cut into plugs 20, which can be used in the aerosol generating article 10 (step 206).

[0301] The crimping process advantageously allows the structure and properties of the nonwoven material to be adjusted to produce a desired profile for the front plug 20.

[0302] To further optimize the properties of the front plug, one or more additional processes may be employed, for example, to ensure that a desired distance between two adjacent folds is achieved. An embossing process may be used, for example, to create a random pattern of relief where the height of the fold is the same as the distance between two adjacent folds. The random relief pattern advantageously prevents two adjacent folds in the nonwoven material having patterns that match and then adhere to each other.

[0303] The desired distance between two adjacent folds is related to the particle size distribution of the aerosol-generating substrate used for the aerosol-generating article.

[0304] The distance to the target between adjacent folds of the plug 20 can be evaluated according to the desired particle size distribution, acceptable particle loss, desired draw resistance of the crumpled forward plug 20, and the length of the crumpled forward plug 20. Although we do not wish to be constrained by theory, the smaller the distance between folds, the higher the draw resistance of the crumpled plug and the lower the likelihood of any particles escaping from the aerosol-generating article.

[0305] Therefore, creases can sometimes be considered particle-retaining features.

[0306] In the embodiments described above, the forward plug 20 of the present invention is formed from a nonwoven material manufactured by the air-ray process 100. However, in other embodiments of the present invention, the forward plug 20 of the present invention may be formed from a nonwoven material manufactured, for example, by the wet-ray process.

[0307] The pull-out resistance of the front plug 20 is related to the desired distance between adjacent folds and the length of the front plug 20. The shorter the distance or the longer the plug, the higher the pull-out resistance. The pull-out resistance is directly related to the width of the sheet being crumpled. The wider the sheet, and the more material is compressed to fit inside the front plug cavity, the higher the pull-out resistance. The front plug 20 of the present invention has been found to have a pull-out resistance similar to that of conventional front plugs containing plastic material.

[0308] Furthermore, it has been found that the front plug 20 of the present invention has higher temperature resistance than conventional plastic-containing front plugs. This improves not only the aesthetics of the product but also its pull resistance. It has also been found that the front plug 20 of the present invention rubs against the inner wall of the heating cavity of the aerosol generator, thereby cleaning dirt and elements that may accidentally enter the heating cavity.

[0309] For the purposes of this specification and the appended claims, unless otherwise indicated, all numbers representing amounts, quantities, proportions, etc., are understood to be modified in all cases by the term “approximately.” Furthermore, all ranges include the disclosed maximum and minimum points and any intermediate ranges within them, which may or may not be specifically listed herein. Thus, in this context, number A is understood as 1 percent of A ± A. In this context, number A may be considered to include a number that falls within the general standard error of the measured value of the characteristic that number A modifies. Number A may deviate by the proportions listed above, provided that in some cases, such as those used in the appended claims, the amount by which A deviates does not substantially affect the fundamental and novel characteristics of the claimed invention. Furthermore, all ranges include the disclosed maximum and minimum points and any intermediate ranges within them, which may or may not be specifically listed herein.

Claims

1. An upstream element for an aerosol generating article, wherein the upstream element is made of a nonwoven material and has particle-holding features including a plurality of folds in the longitudinal direction, Each fold in the longitudinal direction is separated from its adjacent fold in the longitudinal direction by a distance of 25 micrometers to 1000 micrometers. An upstream element wherein the fold in the longitudinal direction, or each fold in the longitudinal direction, has a height, the height of which corresponds to the distance between adjacent folds in the longitudinal direction, and which is between 25 micrometers and 1000 micrometers.

2. The upstream element according to claim 1, wherein the nonwoven material is an airlaid nonwoven material.

3. The upstream element according to claim 2, wherein the airlaid nonwoven material includes a biodegradable material, for example, the airlaid nonwoven material includes cellulose fibers.

4. The upstream element according to claim 3, wherein the airlaid nonwoven material comprises at least 90 weight percent cellulose.

5. The upstream element according to claim 2, claim 3, or claim 4, wherein the airlaid nonwoven material includes a fibrous web material, for example, a web to which the airlaid nonwoven material is bonded.

6. The upstream element according to any one of claims 2 to 5, wherein the airlaid nonwoven material has a weight of at least 15 grams per square meter of surface area, and / or the airlaid nonwoven material has a weight of up to 600 grams per square meter of surface area.

7. The upstream element according to any one of claims 2 to 6, wherein the airlaid nonwoven material is a sheet, for example, the sheet having a width of 400 mm to 500 mm, or the sheet having a width of 120 mm to 210 mm.

8. The upstream element according to any one of claims 2 to 7, wherein the airlaid nonwoven material is a crimped nonwoven material.

9. The upstream element according to any one of claims 2 to 8, wherein the upstream element has a length of 5 millimeters.

10. The upstream element has a length of 1.53 mm H per millimeter of the upstream element. 2 An upstream element according to any one of claims 2 to 9, having an O draw resistance.

11. The upstream element according to any one of claims 2 to 10, wherein the airlaid nonwoven material has an internal bulk density of about 0.13 milligrams per square millimeter.

12. A method for manufacturing an upstream element according to claim 1, wherein the method comprises forming a longitudinal fold in a sheet of nonwoven material, forming a cylinder from the nonwoven material, winding the cylinder, and cutting the cylinder into one or more plugs.

13. The method according to claim 12, wherein the method includes air-raising the sheet of nonwoven material.

14. The method according to claim 12, wherein the method comprises wet laying the sheet or nonwoven material.

15. The method according to claim 13 or 14, further comprising embossing the airlaid nonwoven material or the wetlaid nonwoven material.

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