Aerosol generating substrate element having a double paper wrapper

Abstract

The aerosol-generating substrate element is surrounded by exactly two paper layers that do not extend beyond the aerosol-generating substrate. The aerosol-generating substrate comprises about 10% to about 30% by weight of glycerin. The first and second paper wrappers have a combined thickness in the range of about 60 micrometers to about 200 micrometers. The first paper wrapper does not overlap itself, and the second paper wrapper does not overlap itself.

Description

Technical Field

[0001] The present disclosure relates to a double paper wrapper used in an aerosol generating substrate element. The aerosol generating substrate is tightly surrounded by two paper wrapper layers to form an aerosol generating substrate element.

Background Art

[0002] Aerosol generating articles in which an aerosol generating substrate such as a tobacco-containing substrate is heated rather than burned are well known in the art. Typically, in such heated aerosol generating articles, the aerosol is generated by the transfer of heat from a heat source to an aerosol generating substrate or material physically separated from the heat source, and this aerosol generating substrate or material may be in contact with the heat source, within the heat source, around the heat source, or downstream of the heat source. During use of the aerosol generating article, volatile compounds are released from the aerosol generating substrate by heat transfer from the heat source and entrained in the air drawn through the aerosol generating article. The released compounds condense as they cool to form an aerosol.

[0003] The paper used to wrap the aerosol generating substrate to form the aerosol generating element can absorb aerosol formers, water, and other liquid compounds found in the mainstream smoke or aerosol passing through the aerosol generating article, or moisture or water around the paper. The absorbed liquid may stain or weaken the paper and also adversely affect the appearance and structural integrity of the aerosol generating article. Heated aerosol generating articles are particularly susceptible to wetting and damage due to the high levels of aerosol formers in the aerosol generating substrates of these heated aerosol generating articles. Heated aerosol generating articles are particularly prone to swelling when aerosol components are absorbed by the wrapper, leading to difficult removal from the heating device.

Summary of the Invention

Problems to be Solved by the Invention

[0004] To heat the aerosol generation substrate and release volatile compounds from the aerosol generation substrate, a resistive heating blade may be inserted into the aerosol generation substrate. The resistive heating blade can provide a local heat source within the aerosol generation substrate that can be positioned along the central axis of the aerosol generation substrate. The aerosol generation substrate located at the peripheral portion of the paper wrapper or at the interface with the paper wrapper may not be sufficiently heated by the resistive heating blade located at the center, resulting in an unused aerosol generation substrate within the aerosol generation element.

[0005] In particular, it becomes desirable to provide a visually and mechanically stable aerosol generation substrate for a heated non-combustible aerosol generation substrate containing a high level amount of liquid or aerosol former. Also, it is desirable that this thick paper layer does not affect the taste of the aerosol generated by the aerosol generation substrate element.

Means for Solving the Problems

[0006] It becomes desirable to provide an aerosol generation substrate element that reduces the amount of unused aerosol generation substrate within the aerosol generation element.

[0007] When in proximity to the heating element, it is desirable that this wrapper does not easily burn and does not adversely affect the heating of the heated non-combustible aerosol generation substrate.

[0008] The object of the present invention may be to at least partially solve one or more of the desirable technical advantages described above.

[0009] According to the present disclosure, there is provided an aerosol generating substrate element including a cylindrical aerosol generating substrate, a first paper wrapper, and a second paper wrapper surrounding the aerosol forming substrate. The first paper wrapper and the second paper wrapper have a combined thickness in the range of about 60 micrometers to about 200 micrometers. The first paper wrapper and the second paper wrapper do not extend beyond the aerosol generating substrate. The first paper wrapper does not overlap itself, and the second paper wrapper does not overlap itself.

[0010] An aerosol generating substrate element including a cylindrical aerosol generating substrate, a first paper wrapper, and a second paper wrapper surrounding the aerosol forming substrate is preferred. The cylindrical aerosol generating substrate contains about 10 wt% to about 30 wt% glycerin. The first paper wrapper and the second paper wrapper have a combined thickness in the range of about 60 micrometers to about 200 micrometers. The first paper wrapper and the second paper wrapper do not extend beyond the aerosol generating substrate. The first paper wrapper does not overlap itself, and the second paper wrapper does not overlap itself.

[0011] According to the present disclosure, there is provided an aerosol generating substrate element including a cylindrical aerosol generating substrate, a first paper wrapper, and a second paper wrapper surrounding the first paper wrapper. The first paper wrapper has opposing edges that abut each other to surround the aerosol forming substrate and form a first seam line. The second paper wrapper has opposing edges that abut each other to surround the first paper wrapper and form a second seam line. The first seam line is offset from the second seam line. The first paper wrapper and the second paper wrapper do not extend beyond the aerosol generating substrate.

[0012] Preferably, the first seam line is offset from the second seam line by at least about 5%, or at least about 10%, or at least about 15% around the aerosol generating substrate.

[0013] The aerosol generation substrate is preferably surrounded by no more than two paper layers at any point around the aerosol generation substrate that does not extend beyond the aerosol generation substrate.

[0014] The first paper wrapper and the second paper wrapper may have a combined thickness in the range of about 78 micrometers to about 160 micrometers. The first paper wrapper and the second paper wrapper may have a combined thickness in the range of about 78 micrometers to about 140 micrometers. The first paper wrapper and the second paper wrapper may have a combined thickness in the range of about 90 micrometers to about 140 micrometers. The first paper wrapper and the second paper wrapper may have a combined thickness in the range of about 100 micrometers to about 140 micrometers. The first paper wrapper and the second paper wrapper may have a combined thickness in the range of about 110 micrometers to about 140 micrometers. The first paper wrapper and the second paper wrapper may have a combined thickness in the range of about 125 micrometers to about 140 micrometers. The first paper wrapper and the second paper wrapper may have a combined thickness in the range of about 130 micrometers to about 140 micrometers.

[0015] The first paper wrapper and the second paper wrapper may have a uniform combined thickness that varies by no more than about 30 micrometers, or about 20 micrometers, or about 10 micrometers, or about 5 micrometers at any point around the aerosol generation substrate element.

[0016] The aerosol generation substrate may define a substantially cylindrical shape having a diameter in the range of about 6.8 mm to about 7.1 mm, or about 6.8 mm to about 7.0 mm.

[0017] The first paper wrapper and the second paper wrapper may have a ratio of the combined thickness to the diameter of the tobacco substrate in the range of about 1:120 to about 1:40. The first paper wrapper and the second paper wrapper may have a ratio of the combined thickness to the diameter of the tobacco substrate in the range of about 1:100 to about 1:50. The first paper wrapper and the second paper wrapper may have a ratio of the combined thickness to the diameter of the tobacco substrate in the range of about 1:70 to about 1:50. The first paper wrapper and the second paper wrapper may have a ratio of the combined thickness to the diameter of the tobacco substrate in the range of about 1:60 to about 1:50.

[0018] The aerosol generating substrate may contain a homogenized tobacco material. The homogenized tobacco material may contain, on a dry weight basis, a tobacco material, about 1 percent to about 5 percent of a binder, and about 5 percent to about 30 percent of an aerosol former. The aerosol generating substrate may contain an assembly of sheets of homogenized tobacco material that is preferably crimped.

[0019] The aerosol generating substrate preferably may contain a homogenized tobacco material. The homogenized tobacco material may contain, on a dry weight basis, a tobacco material, about 1 percent to about 5 percent of a binder, and about 10 percent to about 30 percent of glycerin. The aerosol generating substrate may contain an assembly of sheets of homogenized tobacco material that is preferably crimped.

[0020] The aerosol generating substrate may contain a metal inductive heating element. The aerosol generating substrate may contain a plurality of metal inductive heating elements.

[0021] According to the present disclosure, there is provided an aerosol generating system comprising an aerosol generating article described herein and an aerosol generating device including a heating element configured to heat the aerosol generating substrate.

[0022] The heating element may be a resistive heating blade element configured to be inserted into the aerosol generating substrate. The heating element may be an inductive heating element configured to inductively heat a metal inductive heating element embedded within the aerosol generating substrate.

[0023] Advantageously, an aerosol generating substrate element comprising a thick double wrapper can provide a visually and mechanically stable aerosol generating substrate for a heat-not-burn aerosol generating substrate containing a high level amount of liquid or aerosol former. As a result, even when a high amount of wetting agent is included in the aerosol generating substrate, expansion, visible soiling, and physical weakening of the wrapper portion of the aerosol generating article may be reduced.

[0024] Advantageously, an aerosol generating substrate element comprising a thick double wrapper can be formed on a conventional substrate element forming a manufacturing apparatus. Thereby, the processability of the aerosol generating substrate element can be improved and the manufacturing cost can be reduced.

[0025] Advantageously, an aerosol generating substrate element comprising a thick double wrapper can increase the amount of aerosol generating substrate that is uniformly heated and consumed, thus reducing unused or wasted aerosol generating substrate material.

[0026] Advantageously, an aerosol generating substrate element comprising a thick double wrapper can utilize internal heating of the aerosol generating substrate via an inductive or resistive heating element embedded or inserted into the aerosol generating substrate, and the thick double wrapper surrounding the aerosol generating substrate may not adversely affect the heating of the heat-not-burn aerosol generating substrate.

[0027] Conventional cigarettes are ignited when a user applies a flame to one end of the cigarette and draws air through the other end. The localized heat generated by the flame and the oxygen in the air drawn through the cigarette ignites the end of the cigarette, and the resulting combustion generates inhalable smoke. In contrast, in a heated aerosol generating article, the aerosol is generated by heating a flavor generating substrate (such as tobacco). Well-known heated aerosol generating articles include, for example, electrically heated aerosol generating articles and aerosol generating articles in which the aerosol is generated by the transfer of heat from a combustible fuel element or heat source to an aerosol forming substrate that is physically separated therefrom. For example, the aerosol generating article according to the present disclosure has a specific application in an aerosol generating system comprising an electrically heated aerosol generating device having an internal heater blade adapted to be inserted into a rod of an aerosol generating substrate. This type of aerosol generating article is described in the prior art, for example, in European Patent No. EP0822670.

[0028] As used herein, the term "aerosol generating device" refers to a device comprising a heater element that interacts with an aerosol generating substrate of an aerosol generating article to generate an aerosol.

[0029] As used herein, the term "aerosol generating system" refers to a combination of an aerosol generating device and an aerosol generating article.

[0030] As used herein, the term "aerosol generating article" refers to an article comprising an aerosol generating substrate that is heated to generate an inhalable aerosol and delivered to a consumer.

[0031] As used herein, the term "aerosol generating substrate element" is used to denote an aerosol generating substrate wrapped in a paper layer to form a part of an aerosol generating article.

[0032] The term "aerosol generating substrate" refers to a substance having the ability to generate or emit an aerosol. The aerosol generating substrate may be a solid, paste, gel, slurry, or liquid, or may include any combination of solid, paste, gel, slurry, and liquid compounds. The aerosol generating substrate is preferably a solid or a gel composition. The aerosol generating substrate may preferably contain nicotine.

[0033] The term "mouthpiece" is used herein to denote the part of an aerosol generating article designed to come into contact with a consumer's mouth. The mouthpiece can be the part of the aerosol generating article that may include a filter, or in some cases, the mouthpiece can be defined by the extent of a tipping wrapper.

[0034] The terms "upstream" and "downstream" refer to the relative positions of elements of an aerosol generating article described in relation to the direction of the aerosol drawn from the aerosol generating substrate and passing through the mouthpiece.

[0035] The aerosol generating substrate element of the present invention includes an aerosol generating substrate covered with a thick double wrapper. The aerosol generating substrate element includes the aerosol generating substrate and exactly two paper layers surrounding the aerosol generating substrate.

[0036] The aerosol generating substrate element includes a cylindrical aerosol generating substrate element, a first paper wrapper, and a second paper wrapper surrounding the aerosol forming substrate. The first paper wrapper and the second paper wrapper have a combined thickness in the range of about 60 micrometers to about 200 micrometers. The first paper wrapper and the second paper wrapper do not extend beyond the aerosol generating substrate. The first paper wrapper does not overlap itself, and the second paper wrapper does not overlap itself.

[0037] The aerosol generation substrate element includes a cylindrical aerosol generation substrate, a first paper wrapper, and a second paper wrapper. The first paper wrapper has opposing edges that abut against each other to surround the aerosol formation substrate and form a first seam line. The second paper wrapper has opposing edges that abut against each other to surround the first paper wrapper and form a second seam line. The first seam line is offset from the second seam line, and the first paper wrapper and the second paper wrapper do not extend beyond the aerosol generation substrate.

[0038] Preferably, the first seam line can be offset from the second seam line by at least about 5% around the aerosol generation substrate. Preferably, the first seam line can be offset from the second seam line by at least about 10% around the aerosol generation substrate. Preferably, the first seam line can be offset from the second seam line by at least about 15% around the aerosol generation substrate.

[0039] The seam line may define a gap or void with a transverse dimension of less than 10 micrometers, or a transverse dimension of less than 5 micrometers, or a transverse dimension of less than 2 micrometers. Preferably, the seam line does not define a gap. Preferably, the opposing edges of the paper layers abut against each other without overlapping. Preferably, the opposing edges of the paper layers contact each other without overlapping.

[0040] Preferably, the first seam line can be offset from the second seam line in the range of about 5% to about 20% around the aerosol generation substrate. Preferably, the first seam line can be offset from the second seam line in the range of about 5% to about 15% around the aerosol generation substrate. Preferably, the first seam line can be offset from the second seam line in the range of about 10% to about 20% around the aerosol generation substrate.

[0041] The first seam line may be parallel to the second seam line. The first seam line may extend along the entire length of the aerosol generating substrate. The second seam line may extend along the entire length of the aerosol generating substrate. The first seam line may be parallel to the second seam line along the entire length of the aerosol generating substrate.

[0042] The aerosol generating substrate may be surrounded by one or two layers of paper at any point around the aerosol generating substrate that does not extend beyond the aerosol generating substrate. The aerosol generating substrate may be surrounded by one or two layers of paper at any point along the length of the aerosol generating substrate that does not extend beyond the aerosol generating substrate. Preferably, the aerosol generating substrate is surrounded by one or two layers of paper at any point around and along the length of the aerosol generating substrate that does not extend beyond the aerosol generating substrate.

[0043] The combined thickness of the first paper wrapper and the second paper wrapper is in the range of about 60 micrometers to about 200 micrometers. Preferably, the combined thickness of the first paper wrapper and the second paper wrapper is in the range of about 78 micrometers to about 160 micrometers. Preferably, the combined thickness of the first paper wrapper and the second paper wrapper is in the range of about 78 micrometers to about 140 micrometers. Preferably, the combined thickness of the first paper wrapper and the second paper wrapper is in the range of about 90 micrometers to about 140 micrometers. Preferably, the combined thickness of the first paper wrapper and the second paper wrapper is in the range of about 100 micrometers to about 140 micrometers. Preferably, the combined thickness of the first paper wrapper and the second paper wrapper is in the range of about 110 micrometers to about 140 micrometers. Preferably, the combined thickness of the first paper wrapper and the second paper wrapper is in the range of about 125 micrometers to about 140 micrometers. Preferably, the combined thickness of the first paper wrapper and the second paper wrapper is in the range of about 130 micrometers to about 140 micrometers.

[0044] The first paper wrapper may have a thickness in the range of about 25 micrometers to about 175 micrometers. The first paper wrapper may have a thickness in the range of about 50 micrometers to about 150 micrometers. The first paper wrapper may have a thickness in the range of about 75 micrometers to about 125 micrometers. The first paper wrapper may have a thickness in the range of about 100 micrometers to about 140 micrometers.

[0045] The second paper wrapper may have a thickness in the range of about 25 micrometers to about 175 micrometers. The second paper wrapper may have a thickness in the range of about 50 micrometers to about 150 micrometers. The second paper wrapper may have a thickness in the range of about 75 micrometers to about 125 micrometers. The second paper wrapper may have a thickness in the range of about 100 micrometers to about 140 micrometers.

[0046] The first paper wrapper and the second paper wrapper may have substantially equal thicknesses. The first paper wrapper may have a greater thickness than the second paper wrapper. The second paper wrapper may have a greater thickness than the first paper wrapper.

[0047] The first paper wrapper may be fixed to the second paper wrapper. The first paper wrapper may be adhered to the second paper wrapper. The first paper wrapper may be adhered to the second paper wrapper with an adhesive material. The adhesive material may have a thickness in the range of about 1 micrometer to about 30 micrometers, or about 5 micrometers to about 25 micrometers, or about 10 micrometers to about 25 micrometers. The adhesive material may be applied uniformly to the first paper wrapper and the second paper wrapper. The adhesive material may separate the first paper wrapper from the second paper wrapper.

[0048] The first paper wrapper and the second paper wrapper may have a uniform combined thickness that varies by no more than about 30 micrometers at any point around the aerosol-generating substrate element. Preferably, the first paper wrapper and the second paper wrapper may have a uniform combined thickness that varies by no more than about 20 micrometers at any point around the aerosol-generating substrate element. Preferably, the first paper wrapper and the second paper wrapper may have a uniform combined thickness that varies by no more than about 10 micrometers at any point around the aerosol-generating substrate element. Preferably, the first paper wrapper and the second paper wrapper may have a uniform combined thickness that varies by no more than about 5 micrometers at any point around the aerosol-generating substrate element.

[0049] The first paper wrapper may not extend beyond either end of the aerosol-generating substrate. The second paper wrapper may not extend beyond either end of the aerosol-generating substrate. The first paper wrapper and the second paper wrapper may not extend beyond either end of the aerosol-generating substrate.

[0050] The aerosol-generating substrate element includes a cylindrical aerosol-generating substrate, a first paper wrapper, and a second paper wrapper. The first paper wrapper has opposing edges that abut each other to surround the aerosol-forming substrate and form a first seam line where the first paper wrapper does not overlap or cover itself. The second paper wrapper has opposing edges that abut each other to surround the first paper wrapper and form a second seam line where the first seam line does not overlap or cover itself. The first seam line is offset from the second seam line, and the first paper wrapper and the second paper wrapper do not extend beyond the aerosol-generating substrate. Reducing the amount of overlap or covering of the paper wrapper onto itself may help prevent or minimize the void space or air pocket defined between the paper layers.

[0051] The first and second paper wrappers may not extend beyond the ends of the aerosol generating substrate. Preferably, the first and second paper wrappers surround the entire length of the aerosol generating substrate between the ends of the aerosol generating substrate. Preferably, the first and second paper wrappers surround the entire length of the aerosol generating substrate between the ends of the aerosol generating substrate and do not extend beyond one or both ends of the aerosol generating substrate.

[0052] The first and second paper wrappers may surround the aerosol generating substrate to define a substantially cylindrical aerosol generating substrate element. The aerosol generating substrate may define a substantially cylindrical shape having a diameter in the range of about 6.8 mm to about 7.1 mm, or about 6.8 mm to about 7.0 mm. The aerosol generating substrate element may define a substantially cylindrical shape having a diameter in the range of about 7.1 mm to about 7.3 mm, or about 7.15 mm to about 7.25 mm.

[0053] The first paper wrapper and the second paper wrapper have a ratio of the combined paper thickness to the diameter of the tobacco substrate in the range of about 1:120 to about 1:40, or about 1:100 to about 1:50, or about 1:70 to about 1:50, or about 1:60 to about 1:50. Conventionally, the wrapped tobacco substrate may have a ratio of paper thickness to tobacco substrate diameter of about 1:300.

[0054] The first paper wrapper and the second paper wrapper have a ratio of the combined paper thickness to the diameter of the tobacco substrate element in the range of about 1:100 to about 1:40, or about 1:75 to about 1:50, or about 1:65 to about 1:50, or about 1:60 to about 1:50. Conventionally, the wrapped tobacco substrate element may have a ratio of paper thickness to tobacco substrate diameter of about 1:300.

[0055] The aerosol generating substrate element includes an aerosol generating substrate having a diameter in the range of about 6.8 mm to about 7.1 mm, and a first paper wrapper and a second paper wrapper surrounding the aerosol generating substrate, with the combined paper thickness in the range of 78 micrometers to 160 micrometers. It is preferred that the first paper wrapper and the second paper wrapper do not overlap themselves. Preferably, the first paper wrapper and the second paper wrapper do not extend beyond the ends of the aerosol generating substrate. Preferably, the first paper wrapper and the second paper wrapper surround the entire length of the aerosol generating substrate.

[0056] The aerosol generating article may comprise an aerosol generating substrate and a mouthpiece. The mouthpiece may comprise a filter. The tipping wrapper may bond the filter to the aerosol generating substrate. One or more intermediate sections may separate the aerosol generating substrate and the mouthpiece.

[0057] The tipping wrapper may be adhered to the first paper wrapper or the second paper wrapper. The tipping paper preferably extends from the mouthpiece or filter segment to the aerosol generating substrate element. The tipping paper preferably extends from the mouthpiece or filter segment to the aerosol generating substrate element and contacts and adheres to the outer surface of the second paper wrapper. Preferably, the tipping paper extends only over the downstream portion of the aerosol generating substrate element. The tipping wrapper may cover 25% or less of the downstream of the aerosol generating substrate element.

[0058] The aerosol generating substrate may be a solid composition. This composition may include plant-based materials. The aerosol generating substrate may include tobacco, and preferably the tobacco contains volatile tobacco flavor compounds released from the aerosol generating substrate upon heating. The aerosol generating substrate may include homogenized tobacco material, an aerosol former, and a binder.

[0059] Nicotine may be present in the aerosol generating substrate in the range of from about 0.5 to about 10% by weight of nicotine, or from about 0.5 to about 5% by weight of nicotine. Preferably, the aerosol generating substrate may contain from about 1 to about 3% by weight of nicotine, or from about 1.5 to about 2.5% by weight of nicotine, or about 2% by weight of nicotine.

[0060] The aerosol generating substrate may comprise any suitable type(s) of tobacco material or tobacco substitute in any suitable form. The aerosol generating substrate may comprise whole cured tobacco, burley tobacco, maryland tobacco, oriental leaf tobacco, specialty tobacco, homogenized or reconstituted tobacco, or any combination thereof. The aerosol generating substrate may be provided in the form of tobacco cut filler, tobacco leaf lamina, processed tobacco materials such as volume expanded or puffed tobacco, processed tobacco stems such as cut rolled or cut puffed stems, homogenized tobacco, reconstituted tobacco, cast leaf tobacco, or blends thereof, and the like. The term "tobacco cut filler" is used herein to denote a tobacco material mainly formed from the lamina portion of the tobacco leaf. The term "tobacco cut filler" is used herein to denote both a single species of the genus Nicotiana and two or more species of the genus Nicotiana forming a tobacco cut filler blend.

[0061] As used herein, the term "homogenized tobacco" means a material formed by aggregating particulate tobacco. Homogenized tobacco may include reconstituted tobacco or cast leaf tobacco, or a mixture of both. The term "reconstituted tobacco" refers to a paper-like material that can be made from tobacco by-products such as tobacco fines, tobacco dust, tobacco stems, or mixtures of the foregoing. Reconstituted tobacco can be made by extracting soluble chemicals from the tobacco by-products, processing the remaining tobacco fibers into a sheet, and then reapplying the extracted material in a concentrated form onto the sheet. The term "cast leaf tobacco" is used herein to refer to a product resulting from a process well known in the art, which is based on casting a slurry containing ground tobacco particles and a binder (e.g., guar) onto a support surface (such as a belt conveyor), drying the slurry, and removing the dried sheet from the support surface. Exemplary methods for manufacturing these types of aerosol-generating substrates are described in U.S. Patent Nos. 5,724,998, 5,584,306, 4,341,228, 5,584,306, and 6,216,706. Homogenized tobacco may be crimped, entrained, folded, or otherwise compressed into a sheet before being rolled to form a rod. For example, the sheet of homogenized tobacco material used in the present invention may be crimped using a crimping unit of the type described in Swiss Patent No. 691156, which comprises a pair of rotatable crimping rollers. However, it goes without saying that the sheet of homogenized tobacco material used in the present invention may be textured using other suitable machinery and processes that deform or perforate the homogenized tobacco material sheet.

[0062] The aerosol generating substrates used in aerosol generating articles generally contain a higher amount of aerosol former(s) than combustion smoking articles such as cigarettes. Humectants can also be referred to as "aerosol formers". An aerosol former is used to describe any suitable well-known compound or mixture of compounds that facilitates the formation of an aerosol during use and is substantially resistant to thermal decomposition at the operating temperature of the aerosol generating substrate. Suitable aerosol formers are well known in the art and include polyhydric alcohols (such as propylene glycol, triethylene glycol, 1,3-butanediol, glycerin, etc.), esters of polyhydric alcohols (such as glycerin monoacetate, diacetate, triacetate, etc.), and aliphatic esters of monocarboxylic acids, dicarboxylic acids or polycarboxylic acids (such as dimethyl dodecanedioate, dimethyl tetradecanedioate, etc.), but are not limited thereto. Preferred aerosol formers are polyhydric alcohols or mixtures thereof (such as propylene glycol, triethylene glycol, 1,3-butanediol, etc.), and most preferably glycerin or glycerin. The aerosol generating substrate may contain a single aerosol former. Alternatively, the aerosol generating substrate may contain a combination of two or more aerosol formers.

[0063] The aerosol generating substrate may have a high level of aerosol former. As used herein, a high amount of aerosol former means an aerosol former content of more than about 10% by weight, or preferably more than about 15% by weight, or more preferably more than about 20% by weight. The aerosol generating substrate can also have an aerosol former content of from about 10% by weight to about 30% by weight, from about 15% by weight to about 30% by weight, or from about 20% by weight to about 30% by weight. The aerosol generating substrate can also have a glycerin content of from about 10% by weight to about 30% by weight, from about 15% by weight to about 30% by weight, or from about 20% by weight to about 30% by weight.

[0064] The aerosol generating substrate may contain at least about 1 wt%, or at least about 2 wt%, or at least about 5 wt%, or at least about 7 wt%, or at least about 10 wt%, or at least about 12 wt%, or at least about 15 wt%, or at least about 18 wt% of an aerosol former. The aerosol generating substrate may contain an aerosol former in the range of about 1 to about 20 wt%, or about 5 to about 20 wt%, or about 10 to about 20 wt%.

[0065] The aerosol generating substrate may contain at least about 1 wt%, or at least about 2 wt%, or at least about 5 wt%, or at least about 7 wt%, or at least about 10 wt%, or at least about 12 wt%, or at least about 15 wt%, or at least about 18 wt% of glycerin. The aerosol generating substrate may contain glycerin in the range of about 1 to about 20 wt%, or about 5 to about 20 wt%, or about 10 to about 20 wt%.

[0066] The aerosol generating article is preferably generally cylindrical. This allows for a smooth flow of the aerosol. The aerosol generating article may have an outer diameter of, for example, 7.1 millimeters to 7.3 millimeters, 7.15 millimeters to 7.25 millimeters. The aerosol generating article may have a length of, for example, 10 millimeters to 60 millimeters, 15 millimeters to 50 millimeters, or 20 millimeters to 45 millimeters.

[0067] The aerosol generating substrate may contain a flavorant. The plant material provides a flavorant that may impart flavor to the taste of the aerosol generated by the aerosol generating article. A flavorant is any natural or artificial compound that affects the sensory pungency quality of the aerosol. Non-limiting examples of sources of flavorants include mint (such as peppermint and spearmint), coffee, tea, cinnamon, clove, cocoa, vanilla, eucalyptus, geranium, yuzu, and juniper, and combinations thereof.

[0068] The aerosol generating substrate may contain essential oil. The essential oil may provide a flavoring agent that may impart flavor to the taste of the aerosol generated by the aerosol generating article. Suitable essential oils include, but are not limited to, eugenol, peppermint oil, and spearmint oil. A preferred essential oil is eugenol. The essential oil may be present in the aerosol generating substrate in an amount of at least about 0.1% by weight, or at least about 0.5% by weight, or at least about 1% by weight. The essential oil may be present in the aerosol generating substrate in the range of about 0.1% by weight to about 10% by weight, or about 0.1% by weight to about 5% by weight, or about 0.5% by weight to about 2% by weight.

[0069] The aerosol generating substrate may contain homogenized tobacco material. The homogenized tobacco material may contain, on a dry weight basis, tobacco material, about 1 percent to about 5 percent binder, and about 5 percent to about 30 percent aerosol former. The aerosol generating substrate may contain homogenized tobacco material. The homogenized tobacco material may contain, on a dry weight basis, tobacco material, about 1 percent to about 5 percent binder, and about 10 percent to about 30 percent glycerin.

[0070] The sheet of homogenized tobacco used in the aerosol generating article of the present invention may be made by methods well known in the art (e.g., the method disclosed in International Patent Application No. WO-A-2012 / 164009 A2). In a preferred embodiment, the sheet of homogenized tobacco material used in the aerosol generating article is formed from a slurry containing particulate tobacco, guar gum, cellulose fibers, and glycerin by a casting process.

[0071] The aerosol generating substrate may include an assembly of sheets of homogenized tobacco material that are preferably crimped. As used herein, the term "crimped" means a sheet having a plurality of substantially parallel ridges or corrugations. When the aerosol generating article is assembled, the substantially parallel ridges or corrugations preferably extend along or parallel to the longitudinal axis of the aerosol generating article.

[0072] The aerosol generating system may comprise an aerosol generating article described herein and comprising an aerosol generating substrate element coupled to a filter element, and an aerosol generating device comprising a heating element configured to heat the aerosol generating substrate element.

[0073] The heating element may be integral with the aerosol generating device, and the aerosol generating article, which is a consumable, may be removably received within the aerosol generating device.

[0074] The heating element may be a combustible heat source, a chemical heat source, an electrical heat source, a heat sink, or any combination thereof. The heat source is preferably an electrical heat source shaped in the form of a blade that can be inserted into the aerosol generating substrate. Alternatively, the heat source may be configured to surround the aerosol generating substrate and may thus be in the form of a hollow cylinder or any other suitable form of this kind.

[0075]

[0076] The aerosol generating substrate may include an induction heating element or susceptor, or a plurality of induction heating elements or susceptors. The induction heating element or susceptor is heated in the presence of an alternating electromagnetic field or a fluctuating electromagnetic field. When the heating is by induction heating, the fluctuating electromagnetic field is transmitted through the aerosol generating article to the induction heating element or susceptor, whereby the susceptor or induction heating element converts the fluctuating field into thermal energy and thus heats the aerosol generating substrate.

[0077] The induction heating element or susceptor may be formed from any material that can be inductively heated to a temperature sufficient to generate an aerosol from the aerosol generating substrate. The induction heating element or susceptor may include metal or carbon. Preferred induction heating elements or susceptors may include ferromagnetic materials (such as ferrite iron), or ferromagnetic steel or stainless steel. The induction heating element or susceptor may include aluminum. The induction heating element or susceptor may be formed from 400 series stainless steel, such as grade 410, or grade 420, or grade 430 stainless steel. Different materials dissipate different amounts of energy when positioned within an electromagnetic field having similar values of frequency and magnetic field strength. The induction heating element or susceptor is preferably heated to a temperature exceeding 250 degrees Celsius. However, the induction heating element or susceptor is preferably heated to less than 350 degrees Celsius to prevent combustion of the material in contact with the susceptor.

[0078] The aerosol generating substrate may include a metal induction heating element. The metal induction heating element may include a plurality of metal induction heating elements. The metal induction heating element may include a metal induction heating ring element.

[0079] This first paper wrapper may exhibit a range of permeability, which range includes no permeability. The permeability of cigarette paper is determined using the international standard test method ISO 2965:2009, and the results are expressed in cubic centimeters per minute per square centimeter and are referred to as "Coressta units". The permeability of the first paper wrapper described herein may be in the range of about 1 to about 10 Coressta units, about 5 to about 20 Coressta units, or about 1 to about 5 Coressta units.

[0080] The first paper wrapper layer may be formed of any cellulosic material such as paper, wood, fabric, natural fibers, and artificial fibers.

[0081] This second paper wrapper may exhibit a certain range of permeability, which includes no permeability. The permeability of cigarette paper is determined using the international standard test method ISO 2965:2009, and the result is expressed in cubic centimeters per minute per square centimeter and is called the "Coresta unit". The permeability of the second paper wrapper described herein may be in the range of about 1 to about 10 Coresta units, about 5 to about 20 Coresta units, or about 1 to about 5 Coresta units.

[0082] The second paper wrapper layer may be formed of any cellulosic material such as paper, wood, fabric, natural fibers, and artificial fibers.

[0083] The first paper layer or the second paper layer may include a laminate of a paper layer and a metal layer. The first paper layer may include a laminate of a paper layer and a metal layer. The second paper layer may include a laminate of a paper layer and a metal layer. The first paper layer and the second paper layer may include a laminate of a paper layer and a metal layer.

[0084] The metal layer may be an aluminum layer. The first paper layer or the second paper layer may include a laminate of a paper layer and an aluminum layer. The laminate of a paper layer and an aluminum layer may have a uniform thickness in the range of about 78 micrometers to about 160 micrometers, or about 78 micrometers to about 140 micrometers, or about 100 micrometers to about 140 micrometers, or about 125 micrometers to about 140 micrometers. The laminate of a paper layer and a metal layer may not extend beyond the end of the aerosol generating substrate.

[0085] The draw resistance (RTD) of the aerosol generating article after insertion into the aerosol generating device is preferably about 80 mmWG to about 140 mmWG, more preferably about 100 mmWG to about 120 mmWG.

[0086] The draw resistance used in this specification is expressed in the pressure unit of "mmWG" or "millimeter of water column" and is measured in accordance with ISO 6565:2002. The draw resistance (RTD) of the rod of the aerosol generation substrate is preferably about 50 mmWG to about 80 mmWG. The RTD of the rod of the aerosol generation substrate is preferably about 5 mmWG to about 8 mmWG per millimeter of the rod length.

[0087] All scientific and technical terms used in this specification have the meanings generally used in the relevant technical field, unless otherwise specified. The definitions provided in this specification are provided to facilitate the understanding of specific terms frequently used in this specification.

[0088] As used in this specification and the appended claims, the singular forms "a", "an", and "the" include embodiments having a plural object, unless the context clearly dictates otherwise.

[0089] The term "or" as used in this specification and the appended claims is generally used in the sense of "and / or", unless the context clearly dictates otherwise.

[0090] The terms "have", "having", "include", "including", "comprise", "comprising", or the like used in this specification are used in an unrestricted sense and generally mean "including but not limited to". Of course, "consisting essentially of", "consisting of", and the like are subsumed under "comprising" and the like.

[0091] The terms "preferred" and "preferably" refer to embodiments of the present invention that may provide certain advantages under certain circumstances. However, under the same or other circumstances, other embodiments may also be preferred. Moreover, the recitation of one or more preferred embodiments is not intended to imply that other embodiments are not useful, nor is it intended to exclude other embodiments from the scope of the disclosure, including the claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0092]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

[0093] The aerosol generating articles illustrated in FIGS. 1-6 exemplify one or more embodiments of the above-described aerosol generating articles, components of aerosol generating articles, or aerosol generating systems. The schematic diagrams are not necessarily to scale and are presented for purposes of illustration and not limitation. The drawings illustrate one or more aspects described in the present disclosure. However, it goes without saying that other aspects not illustrated in the drawings also fall within the scope and spirit of the present disclosure.

[0094] The aerosol generating article 10 of FIG. 1 shows an aerosol generating substrate element 12 that includes an aerosol generating substrate 20 wrapped in a double paper wrapper 30. The intermediate section 24 separates the filter element 22 from the aerosol generating substrate element 12. The aerosol generating substrate element 12, the intermediate section 24, and the filter element 22 are aligned in a sequential order from the distal end 13 to the proximal end 11 and form a cylinder. The tipping paper or tipping wrapper 40 surrounds the aerosol generating article 10 and joins the aerosol generating substrate element 12 to the intermediate section 24 and the filter element 22.

[0095] The intermediate section 24 may comprise one or more of a hollow cellulose acetate tube or a polylactic acid filter segment. The filter element 22 may define a mouthpiece segment and may be formed of a cellulose acetate material. The aerosol generating substrate element 12, the intermediate section 24, and the filter element 22 may be individually wrapped in paper layers and then joined to each other with tipping paper 40 or tipping wrapper 40. In particular, the aerosol generating substrate element 12 is wrapped in a double paper wrapper 30 as described herein.

[0096] The aerosol generating article 10 has a mouth-side end or proximal end 11 and an upstream distal end 13 located at the end of the article opposite the mouth-side end 11. The aerosol generating article 10 shown in FIG. 1 is particularly suitable for use in an electrically operated aerosol generating device that includes a heater for heating the aerosol generating substrate element 12.

[0097] FIG. 2 is a schematic cross-sectional view of a first paper wrapper 31 and a second paper wrapper 32 or a double paper wrapper 30 before being wrapped around the aerosol generating substrate 20. FIG. 3 is a schematic cross-sectional view of the aerosol generating substrate element 12 along line 3-3 of FIG. 1. FIG. 4 is a schematic cross-sectional view of the aerosol generating substrate element 12 along line 4-4 of FIG. 3.

[0098] The first paper wrapper 31 has opposing edges that abut each other to surround the aerosol-forming substrate 20 and form a first seam line 35. The second paper wrapper 32 has opposing edges that abut each other to surround the first paper wrapper 31 and form a second seam line 34. The first seam line 35 is offset from the second seam line 34, and the first paper wrapper 31 and the second paper wrapper 32 do not extend beyond the aerosol-generating substrate 20 or beyond the ends 25, 26 of the aerosol-generating substrate 20.

[0099] The double paper wrapper 30 surrounds the aerosol-generating substrate 20 and defines a substantially cylindrical aerosol-generating substrate element 12. The aerosol-generating substrate 20 defines a substantially cylindrical shape having a diameter 23 in the range of about 6.8 mm to about 7.1 mm, or about 6.8 mm to about 7.0 mm. The aerosol-generating substrate element 12 defines a substantially cylindrical shape having a diameter 33 in the range of about 7.1 mm to about 7.3 mm, or about 7.15 mm to about 7.25 mm.

[0100] The double paper wrapper 30 has a thickness T in the range of about 60 micrometers to about 200 micrometers. The double paper wrapper 30 preferably may have a thickness in the range of about 78 micrometers to about 160 micrometers, or about 78 micrometers to about 140 micrometers, or about 90 micrometers to about 140 micrometers, or about 100 micrometers to about 140 micrometers, or about 110 micrometers to about 140 micrometers, or about 125 micrometers to about 140 micrometers, or about 130 micrometers to about 140 micrometers.

[0101] The double paper wrapper 30 has a ratio of the paper thickness T to the diameter 23 of the tobacco substrate in the range of about 1:120 to about 1:40, or about 1:100 to about 1:50, or about 1:70 to about 1:50, or about 1:60 to about 1:50.

[0102] The double paper wrapper 30 surrounds the entire periphery of the aerosol generating substrate 20 such that the first paper wrapper 31 does not overlap itself and the second paper wrapper 32 does not cover itself. The double paper wrapper 30 defines a paper layer of two layers or less at any point around the aerosol generating substrate element 12.

[0103] FIG. 5 is a schematic cross-sectional view of the aerosol generating system 201. FIG. 6 is a schematic cross-sectional view of the heating blade 230 inserted into the aerosol generating substrate element 12. The aerosol generating article 10 may be used with the aerosol generating device 200 as illustrated in FIGS. 5 and 6.

[0104] The aerosol generating device 200 includes a housing 210 that defines a container 220 configured to receive the aerosol generating article 10. The aerosol generating device 200 also includes a heating blade element 230 configured to penetrate the aerosol generating substrate element 12 of the aerosol generating article 10. The heating blade element 230 may comprise an electric resistance heating component. In addition, the device 200 includes a power source 240 and control electronics 250 that cooperate to control the heating of the heating blade element 230.

[0105] The aerosol generating article 10 exemplifies an aerosol generating substrate element 12, an intermediate section 24, and a filter element 22 that are aligned in a sequential order from the distal end 13 to the proximal end 11 to form a cylinder. The distal end 13 of the aerosol generating article 10. The aerosol generating substrate 12 has a length of about 12 millimeters. The aerosol generating substrate 12 has a cylindrical shape and a substantially circular cross-section. The aerosol generating substrate 12 may comprise an assembly of sheets of homogenized tobacco material. The sheets of homogenized tobacco material may contain about 10 weight percent glycerin on a dry basis. The intermediate section 24 may be a hollow cellulose acetate tube having a length of about 8 millimeters and a thickness of 1 millimeter. The mouthpiece segment or filter element 22 may comprise a plug of 8 denier cellulose acetate tow per filament and have a length of about 7 millimeters.

[0106] Figure 6 illustrates a heating blade element 230 disposed within the aerosol generating substrate 12. The heating blade element 230 may heat the aerosol generating substrates 12, 20 of the aerosol generating article 10. Heating of the aerosol generating substrate 12 generates an aerosol containing nicotine in the aerosol generating substrate 12, and the aerosol can move out of the aerosol generating article 10 at the proximal end 11.

[0107] The heating blade element 230 may have a width 233 of about 5 mm. The aerosol generating substrate 20 defines a substantially cylindrical shape having a diameter 23 in the range of about 6.8 mm to about 7.1 mm. The aerosol generating substrate element 12 defines a substantially cylindrical shape having a diameter 33 in the range of about 7.1 mm to about 7.3 mm. The heating blade element 230 may be positioned within about 1 mm from the double paper wrapper 30.

[0108] In some embodiments, the heating mechanism may be by induction in which the heating element emits radio magnetic radiation that is absorbed by one or more metal induction heating elements when the aerosol generating article 10 is positioned within the container 220 of the aerosol generating device 200.

[0109] When the aerosol generating article 10 is releasably received within the aerosol generating device 200 and on the heating blade element 230, the aerosol generating device 200 operates to heat the aerosol generating substrate 12 to a temperature of approximately 375 degrees Celsius. When the user sucks on the mouth-side end 11 of the aerosol generating article 10, the volatile compounds generated from the aerosol generating substrate 12 are drawn downstream through the aerosol generating article 10, condense to form an aerosol, which is drawn into the user's mouth through the mouthpiece 11 of the aerosol generating article 10.

[0110] The above exemplary embodiments are not limiting. Other embodiments consistent with the above exemplary embodiments will be apparent to those skilled in the art.

Claims

1. An aerosol generating substrate element, comprising: a cylindrical aerosol generating substrate containing about 10 wt% to about 30 wt% glycerin; a first paper wrapper having opposing edges that abut each other to surround the aerosol generating substrate and form a first seam line; a second paper wrapper having opposing edges that abut each other to surround the first paper wrapper and form a second seam line; wherein the first seam line is offset from the second seam line, and the first paper wrapper and the second paper wrapper do not extend beyond the aerosol generating substrate, the aerosol generating substrate element.

2. The aerosol generating substrate element according to claim 1, wherein the first seam line is offset from the second seam line by at least about 5%, or at least about 10%, or at least about 15% around the circumference of the aerosol generating substrate.

3. The aerosol generating substrate element according to claim 1 or 2, wherein the aerosol generating substrate is surrounded by no more than two layers of paper that do not extend beyond the aerosol generating substrate at any point around the circumference of the aerosol generating substrate.

4. The aerosol generating substrate element according to any one of claims 1 to 3, wherein the first paper wrapper and the second paper wrapper have a combined thickness in the range of about 60 micrometers to about 200 micrometers, or 78 micrometers to about 160 micrometers, or 78 micrometers to about 140 micrometers, or about 100 micrometers to about 140 micrometers, or about 125 micrometers to about 140 micrometers.

5. The aerosol generating substrate element according to any one of claims 1 to 4, wherein the first paper wrapper and the second paper wrapper have a uniform combined thickness that does not differ by more than about 30 micrometers, or more than about 20 micrometers, or more than about 10 micrometers, or more than about 5 micrometers at any point around the circumference of the aerosol generating substrate element.

6. The aerosol generating substrate element according to any one of claims 1 to 5, wherein the aerosol generating substrate has a diameter in the range of about 6.8 mm to about 7.1 mm.

7. The aerosol generating substrate element according to any one of claims 1 to 6, wherein the first paper wrapper and the second paper wrapper have a ratio of the combined paper thickness to the diameter of the tobacco substrate in the range of about 1:120 to about 1:40, or about 1:100 to about 1:

50.

8. The aerosol generating substrate element according to any one of claims 1 to 7, wherein the aerosol generating substrate contains a homogenized tobacco material.

9. The aerosol generating substrate element according to claim 8, wherein the homogenized tobacco material contains a tobacco material, a binder of about 1 percent to about 5 percent, and glycerin of about 10 percent to about 30 percent on a dry weight basis.

10. The aerosol generating substrate element according to any one of claims 1 to 9, wherein the aerosol generating substrate contains a metal induction heating element.

11. The aerosol generating substrate element according to any one of claims 1 to 10, wherein the aerosol generating substrate contains a plurality of metal induction heating elements.

12. An aerosol generating system, comprising: an aerosol generating article including the aerosol generating substrate element according to any one of claims 1 to 11 coupled to a filter element; and an aerosol generating device comprising a heating element configured to heat the aerosol generating substrate element.

13. The aerosol generating system according to claim 12, wherein the heating element is a resistive heating blade element configured to be inserted into the aerosol generating substrate element.

14. The aerosol generating system according to claim 12, wherein the heating element is an induction heating element configured to inductively heat a metal induction heating element embedded in the aerosol generating substrate element.

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