Aerosol-generating article having multiple air entry zones

Abstract

An aerosol-generating article (1) for generating an aerosol upon heating is provided. The aerosol-generating article comprises an aerosol-forming substrate rod (12) and a filter positioned downstream of the aerosol-forming substrate rod. The aerosol-forming substrate rod and filter are assembled within a wrapper (22). The aerosol-generating article comprises first and second air entry zones (15, 115) located on the wrapper. The first and second air entry zones are configured to allow air to enter the interior of the aerosol-generating article, respectively. The level of air entry into the interior of the aerosol-generating article through the first air entry zone is configured to be greater than the level of air entry into the interior of the aerosol-generating article through the second air entry zone. Also provided is an aerosol generation system (100) comprising the aerosol-generating article and the aerosol generating device (10).

Description

[Technical Field]

[0001] The present invention relates to an aerosol-generating article for generating an aerosol upon heating. Also described herein is an aerosol-generating system comprising the aerosol-generating article and an aerosol-generating device. [Background technology]

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

[0003] Numerous prior art documents disclose aerosol generating devices for consuming aerosol-generating articles, including, for example, electrically heated aerosol generating devices in which the aerosol is generated by heat transfer from one or more electric heater elements of the aerosol generating device to an aerosol-forming substrate of a heated aerosol-generating article.

[0004] Typically, an aerosol-generating article is specifically adapted for use in conjunction with a particular aerosol-generating device, or an aerosol-generating device is specifically adapted for use in conjunction with a particular aerosol-generating article. In particular, it may be necessary to avoid using a particular aerosol-generating article with a particular aerosol-generating device. This may be because the particular article is suited to being heated by the heating element of a particular aerosol-generating device, as such a device may overheat the particular aerosol-generating article or not heat other aerosol-generating articles.

[0005] It is therefore desirable to provide an aerosol-generating article that is adapted for use in an aerosol-generating system that prevents the use of an aerosol-generating article that is not compatible with the aerosol-generating device. Summary of the Invention

[0006] Provided herein is an aerosol-generating article for generating an aerosol upon heating. The aerosol-generating article comprises a rod of aerosol-forming substrate and a filter positioned downstream of the rod of aerosol-forming substrate. The rod of aerosol-forming substrate and the filter are assembled within a wrapper. The aerosol-generating article comprises first and second air entry zones located on the wrapper. The first and second air entry zones are each configured to allow air to enter the interior of the aerosol-generating article. The level of air entry into the interior of the aerosol-generating article through the first air entry zone is configured to be greater than the level of air entry into the interior of the aerosol-generating article through the second air entry zone.

[0007] Provided herein is an aerosol-generating article for generating an aerosol upon heating. The aerosol-generating article may include a rod of aerosol-forming substrate. The aerosol-generating article may include a filter positioned downstream of the rod of aerosol-forming substrate. The rod of aerosol-forming substrate and the filter may be assembled within a wrapper. The aerosol-generating article may include first and second air entry zones located on the wrapper. The first and second air entry zones may each be configured to allow air to enter the interior of the aerosol-generating article. The level of air entry into the interior of the aerosol-generating article through the first air entry zone may be configured to be greater than the level of air entry into the interior of the aerosol-generating article through the second air entry zone.

[0008] As used herein, the downstream section may refer to one or more components located downstream of the rod of the aerosol-forming substrate. A filter may be the downstream section. The filter may form part of the downstream section. The downstream section may include a filter.

[0009] Provided herein is an aerosol-generating article for generating an aerosol upon heating. The aerosol-generating article may comprise a rod of an aerosol-forming substrate. The aerosol-generating article may comprise a downstream section positioned downstream of the rod of the aerosol-forming substrate. The rod and downstream section of the aerosol-forming substrate may be assembled within a wrapper. The aerosol-generating article may comprise first and second air entry zones located on the wrapper. The first and second air entry zones may each be configured to allow air to enter the interior of the aerosol-generating article. The level of air entry into the interior of the aerosol-generating article through the first air entry zone may be configured to be greater than the level of air entry into the interior of the aerosol-generating article through the second air entry zone.

[0010] The aerosol-generating article may comprise an aerosol former. The aerosol-forming substrate may have an aerosol former content of greater than about 10 percent on a dry weight basis.

[0011] The aerosol-generating article may be configured to be used with a particular aerosol-generating device to form an aerosol-generating system. The present disclosure also relates to aerosol-generating systems. As used herein, the term "aerosol-generating device" refers to a device that includes a heating element that interacts with the aerosol-generating substrate of the aerosol-generating article to generate an aerosol.

[0012] The aerosol generating device of the aerosol generating system may have a distal end and a mouth end. The aerosol generating device may include a housing. The housing may define a device cavity for removably receiving an aerosol-generating article at the mouth end of the device. The aerosol generating device may include a heater for heating the aerosol-forming substrate when the aerosol-generating article is received in the device cavity. The aerosol generating device may include an airflow channel extending between a channel inlet and a channel outlet. The airflow channel may be configured to establish fluid communication between the interior of the device cavity and the exterior of the aerosol generating device. The aerosol generating system or device may be configured such that when the aerosol-generating article is received in the device cavity, fluid communication between the interior of the aerosol-generating article and the exterior of the aerosol generating device can be established by fluid communication established between a first air entry zone of the aerosol-generating article received in the device cavity and the airflow channel of the aerosol generating device.

[0013] To consume the aerosol-generating article of the present invention and generate an aerosol within an aerosol-generating device of an aerosol generation system, fluid communication must be established between the interior of the aerosol-generating article and the exterior of the aerosol-generating device. During consumption, a user may inhale the aerosol-generating article so that the user can experience and consume the aerosol being generated within the aerosol-generating article. Through this withdrawal action, air may flow from the exterior of the aerosol-generating device, through the aerosol-generating device, into the aerosol-generating article, and through the aerosol-generating article to transport the aerosol generated within the article to the user's mouth.

[0014] The use of compatible aerosol-generating articles with aerosol-generating devices is ensured by configuring the aerosol generation system so that fluid communication between the interior of the aerosol-generating article and the exterior of the aerosol-generating device is established by fluid communication established between a first air entry zone of the aerosol-generating article received within the device cavity and an airflow channel of the aerosol-generating device. For use in the aerosol generation system of the present invention, a compatible aerosol-generating article must have a first air entry zone configured to establish fluid communication between the first air entry zone of the aerosol-generating article and the airflow channel of the aerosol-generating device when received within the device cavity. Furthermore, a compatible aerosol-generating device must have an airflow channel configured to establish fluid communication with the first air entry zone of the aerosol-generating article received within the device.

[0015] Fluid communication between the interior of the aerosol-generating article and the exterior of the aerosol-generating device can be established by an airflow channel outlet of the aerosol-generating device overlaying or overlapping a first air entry zone of the aerosol-generating article received within the device cavity. Accordingly, a compatible aerosol-generating article must have a first air entry zone configured such that, when received within the device cavity, the airflow channel outlet of the aerosol-generating article overlays or overlaps the first air entry zone of the aerosol-generating article. Furthermore, a compatible aerosol-generating device must have an airflow channel whose outlet is configured such that, when received within the device, it overlays or overlaps the first air entry zone of the aerosol-generating article.

[0016] If an incompatible aerosol-generating article is used with an aerosol-generating device of the aerosol generation system of the present disclosure, the user may be unable to use the aerosol generation system and consume, or at least not fully experience, the incompatible aerosol-generating article. Furthermore, if a compatible aerosol-generating article is used with a different aerosol-generating device that does not belong to the aerosol generation system of the present disclosure, the user may be unable to use the aerosol generation system and consume, or at least not fully experience, the compatible aerosol-generating article. This is because, if alignment of the airflow channel outlet of the aerosol-generating device with the first air entry zone of the aerosol-generating article does not occur, fluid communication between the interior of the aerosol-generating article and the exterior of the aerosol-generating device may not be properly or fully established.

[0017] Fluid communication between the exterior of the aerosol-generating device and the interior of the aerosol-generating article may be established by partial or complete overlap or alignment between the outlet of the airflow channel of the device and the first air entry zone of the article.

[0018] Fluid communication between the exterior of the aerosol-generating device and the interior of the aerosol-generating article may be established by partial or complete overlap or alignment between the airflow channel of the device and the first air entry zone of the article.

[0019] By providing a first air entry zone and a second air entry zone, and by configuring the level of air entry into the interior of the aerosol-generating article through the first air entry zone to be greater than the level of air entry into the interior of the aerosol-generating article through the second air entry zone, the aerosol-generating article of the present invention can provide both a primary air intake zone in the first air entry zone and a ventilation zone in the second air entry zone. During use with a compatible aerosol generating device, the first air entry zone can allow the majority of the air to enter the aerosol-generating article, while the second air entry zone can provide ventilation for the generated aerosol stream, cooling the stream and improving the consumer experience.

[0020] As used herein, the term "longitudinal" refers to a direction corresponding to the main longitudinal axis of the aerosol-generating article or device extending between the upstream and downstream ends of the aerosol-generating article or device.

[0021] As used herein, the terms "upstream" and "downstream" describe the relative location of an aerosol-generating article or element or portion of an element of a device with respect to the direction in which aerosol is transported through the aerosol-generating article during use.

[0022] The term "mouth end" refers to the portion of an element or component that is configured to be placed in or near the user's mouth during normal use of the element or component. The mouth end of a component may also correspond to the downstream end of the same component. For example, the mouth end of an aerosol-generating article may also be the downstream end of the article. The mouth end of an aerosol-generating article or device is configured to be placed in or near the consumer's mouth during normal use. The mouth end of an aerosol-generating device may also be referred to as the proximal end of the aerosol-generating device.

[0023] During use, air is primarily drawn longitudinally through the aerosol-generating article. Outside the device, air may be drawn through the article via the upstream end.

[0024] The term "transverse" refers to a direction perpendicular to the longitudinal axis. Any reference to a "cross section" of an aerosol-generating article or a component of an aerosol-generating article refers to a transverse cross section, unless otherwise specified.

[0025] The term "length" refers to the dimension of an aerosol-generating article or device component along its longitudinal axis.

[0026] The device cavity may be referred to as the heating chamber of the aerosol-generating device. The device cavity may extend between a distal end and an oral or proximal end. The distal end of the device cavity may be a closed end, and the oral or proximal end of the device cavity may be an open end. The aerosol-generating article may be inserted into the device cavity or heating chamber through the open end of the device cavity. The device cavity may be cylindrical in shape to fit the same shape of the aerosol-generating article.

[0027] The phrase "received within" may refer to the fact that a component or element is completely or partially received within another component or element. For example, the phrase "an aerosol-generating article is received within a device cavity" refers to the aerosol-generating article being completely or partially received within the device cavity of the aerosol-generating article. When the aerosol-generating article is received within the device cavity, the aerosol-generating article may abut the distal end of the device cavity. When the aerosol-generating article is received within the device cavity, the aerosol-generating article may be substantially proximate to the distal end of the device cavity. The distal end of the device cavity may be defined by an end wall.

[0028] The length of the device cavity may be about 10 mm to about 50 mm. The length of the device cavity may be about 20 mm to about 40 mm. The length of the device cavity may be about 25 mm to about 30 mm. The length of the device cavity may be the same as or longer than the length of the rod of the aerosol-forming substrate.

[0029] The diameter of the device cavity may be about 4 mm to about 50 mm. The diameter of the device cavity may be about 4 mm to about 30 mm. The diameter of the device cavity may be about 5 mm to about 15 mm. The diameter of the device cavity may be about 6 mm to about 12 mm. The diameter of the device cavity may be about 7 mm to about 10 mm. The diameter of the device cavity may be about 7 mm to about 8 mm.

[0030] The diameter of the device cavity may be the same as or larger than the diameter of the aerosol-generating article. The diameter of the device cavity may be the same as the diameter of the aerosol-generating article to establish a tight fit with the aerosol-generating article.

[0031] The device cavity may be configured to establish a tight fit with an aerosol-generating article received within the device cavity. A tight fit may refer to a slip fit. The aerosol-generating device may include a peripheral wall. Such a peripheral wall may define the device cavity or a heating chamber. The peripheral wall defining the device cavity may be configured to engage in a tight fit with an aerosol-generating article received within the device cavity such that, when received within the device, there is substantially no gap or empty space between the peripheral wall defining the device cavity and the aerosol-generating article.

[0032] Such an airtight fit may establish an airtight fit or configuration between the device cavity and the aerosol-generating article received therein. Such an airtight configuration may mean that air can only be drawn into the interior of the aerosol-generating article through alignment or overlap of the airflow channel outlet and the first air entry zone. In such an airtight configuration, there are substantially no gaps or empty spaces between the peripheral walls defining the device cavity and the aerosol-generating article through which the air flows. Thus, when an incompatible aerosol-generating article is used with an aerosol-generating device, such alignment does not occur, and therefore air may not be drawn through the incompatible aerosol-generating article.

[0033] The tight fit with the aerosol-generating article may be established along the entire length of the device cavity or along a portion of the length of the device cavity. The tight fit may be established at a location downstream of the first air entry zone of the aerosol-generating article. The portion of the peripheral wall configured to establish such a tight fit may be referred to as a sealing portion of the peripheral wall. Such a tight fit may be established when an airflow channel is defined within the thickness of the peripheral wall of the aerosol-generating device. The sealing portion of the peripheral wall may be defined along the entire length of the device cavity.

[0034] When the airflow channel is defined on the inner surface of the peripheral wall of the device housing, a portion of the peripheral wall between the airflow channel and the distal end of the device cavity may define a sealing portion of the peripheral wall, ensuring that air does not flow beyond the airflow channel toward the upstream end of the aerosol-generating article. The portion of the peripheral wall between the airflow channel and the distal end of the device cavity may form an airtight arrangement with the upstream portion of the aerosol-generating article when received within the device.

[0035] The sealing portion of the peripheral wall may be configured to establish an airtight fit with a portion of the aerosol-generating article at a location downstream of a first air entry zone of the aerosol-generating article. The sealing portion of the peripheral wall may be configured to establish an airtight fit with a portion of the aerosol-generating article at a location downstream of a second air entry zone of the aerosol-generating article.

[0036] The diameter of the device cavity may vary along the longitudinal axis of the aerosol generation device. The diameter of the device cavity may decrease from the distal end of the device cavity to the sealing portion of the peripheral wall.

[0037] The diameter of the device cavity may increase in a direction from the sealing portion of the peripheral wall toward the distal end of the device cavity. The diameter of the device cavity between the distal end of the device cavity and the sealing portion of the peripheral wall may be larger than the diameter of the remainder of the device cavity. The diameter of the device cavity may increase in a direction away from the sealing portion of the peripheral wall and in a direction away from the oral end of the device.

[0038] By providing a portion of the device cavity with a larger diameter or multiple larger diameters than other portions of the device cavity, the device cavity can define a gap or chamber around the upstream portion of the aerosol-generating article when received within the device. In such embodiments, alignment or overlap between the first air entry zone and the first outlet of the device's airflow channel may not be necessary to ensure fluid communication between the exterior of the device and the interior of the article. Air must still be admitted into the article via the first air entry zone. Air entering the device cavity via the first outlet of the airflow channel can enter such a gap or chamber and then be drawn into the article via the first air entry zone. Such a gap or chamber provides a cushion of air around that upstream portion of the article, which can either be heated by the device's heater or act as a cushion of cooling air surrounding the article.

[0039] The aerosol generating device may comprise a peripheral wall defining a device cavity, and the aerosol generating device may comprise a peripheral protrusion extending from the peripheral wall into the device cavity, the peripheral protrusion configured, when received within the aerosol generating device, to establish an airtight fit with a portion of the aerosol-generating article at a position downstream of the first air entry zone of the aerosol-generating article.

[0040] The diameter of the device cavity may be larger than the diameter of the aerosol-generating article, and the inner diameter of the peripheral protrusion may be the same as the diameter of the aerosol-generating article so that a tight fit is established between the article and the peripheral protrusion after the article is received in the aerosol-generating device. The inner diameter of the peripheral protrusion may be smaller than the diameter of the aerosol-generating article, which may ensure that an airtight fit is more reliably established.

[0041] Establishing an airtight fit with the aerosol-generating article downstream of the first air entry zone further ensures that air can only enter the interior of the aerosol-generating article through alignment of the airflow channel outlet with the first air entry zone, which may be achieved by either a sealing portion of the peripheral wall or a peripheral protrusion, both of which are discussed above.

[0042] When the aerosol-generating article is received within the device cavity, the upstream end of the aerosol-generating article may be blocked so that air is substantially prevented from entering the aerosol-generating article through its upstream end. However, when the aerosol-generating article is not received within the aerosol-generating device, air may flow through the aerosol-generating article through its upstream end. When the article is received or inserted within the device, the upstream end of the aerosol-generating article may be located around the distal end of the device cavity so that air can no longer flow through the upstream end of the article. Therefore, air flowing through the airflow channel may only be drawn through the article via the first air entry zone. The upstream end of the aerosol-generating article may be defined by the upstream end of the aerosol-forming substrate rod.

[0043] The aerosol generating device may include an airflow channel extending between the channel inlet and the channel outlet. The airflow channel may be configured to establish fluid communication between the interior of the device cavity and the exterior of the aerosol generating device. The airflow channel of the aerosol generating device may be defined within the housing of the aerosol generating device to enable fluid communication between the interior of the device cavity and the exterior of the aerosol generating device. When an aerosol-generating article is received within the device cavity, the airflow channel may be configured to provide air flow into the article to deliver the generated aerosol to a user who draws from the mouth end of the article.

[0044] The airflow channel of the aerosol generating device may be defined within or by the peripheral wall of the housing of the aerosol generating device. In other words, the airflow channel of the aerosol generating device may be defined within the thickness of the peripheral wall, or by the inner surface of the peripheral wall, or a combination of both. The airflow channel may be partially defined by the inner surface of the peripheral wall, or partially defined within the thickness of the peripheral wall. The inner surface of the peripheral wall defines the periphery of the device cavity.

[0045] The airflow channel of the aerosol generating device may extend from an inlet located at the oral or proximal end of the aerosol generating device to an outlet located away from the oral end of the device. The airflow channel may extend along a direction parallel to the longitudinal axis of the aerosol generating device. The airflow channel outlet is configured such that when a compatible aerosol-generating article is received within the device cavity, the outlet covers a first air entry zone of the article.

[0046] The airflow channel may be provided with two or more outlets, one for each air entry zone provided in the article configured for use with the aerosol generating device. For example, if the aerosol-generating article has a first air entry zone and a second air entry zone, the corresponding airflow channel of the aerosol generating device may have at least one first outlet for covering the first air entry zone and at least one second outlet for covering the second air entry zone when the aerosol-generating article is fully received within the aerosol generating device. Thus, the aerosol generating system may be configured such that, when the aerosol-generating article is received within the device cavity, fluid communication between the interior of the aerosol-generating article and the exterior of the aerosol generating device is established by fluid communication established between the first and second air entry zones of the aerosol-generating article received within the device cavity and the airflow channel of the aerosol generating device.

[0047] When an airflow channel is defined within the peripheral wall of the device, the airflow channel may include a first portion extending from the channel inlet in the axial direction of the device and a second portion extending from the end of the first portion in a transverse or radial direction relative to the channel outlet. Consequently, the airflow channel may include a bend or elbow to connect the airflow channel inlet and outlet. When the airflow channel includes two or more outlets along its length, the airflow channel may include additional channel portions extending transversely from the first portion to each of the additional outlets. When the airflow channel includes a single outlet, the airflow channel may include an L-shaped bend or elbow.

[0048] When the airflow channel is defined by the inner surface of the peripheral wall, the length of the airflow channel may be directly exposed to the device cavity, i.e., the longitudinal side of the airflow channel may be open to the device cavity. The thickness of the portion of the peripheral wall defining the airflow channel may be less than the thickness of the remainder of the peripheral wall. The diameter of the portion of the peripheral wall defining the airflow channel may be greater than the diameter of the remainder of the peripheral wall. In such embodiments, the airflow channel may be annular in shape, such that the airflow channel surrounds the device cavity and the aerosol-generating article received within the device cavity.

[0049] In embodiments in which the airflow channel is defined by the inner surface of the peripheral wall of the housing, the entire length of the airflow channel may be exposed or open to the device cavity and, therefore, to the aerosol-generating article received within the device. In such embodiments, the airflow channel is configured to cover all air entry zones of compatible aerosol-generating articles to establish fluid communication between the exterior of the aerosol-generating device and the interior of the aerosol-generating article. In such embodiments, the outlet of the airflow channel may be considered the open side of the airflow channel, i.e., the side of the airflow channel that is exposed or open to the device cavity.

[0050] The length of the airflow channel may be less than the length of the device cavity. The length of the airflow channel refers to the longitudinal or axial distance that the airflow channel extends.

[0051] The airflow channel may be configured such that a first outlet of the airflow channel is aligned with or positioned to cover a first air entry zone of an aerosol-generating article received within the device cavity. The airflow channel may extend from a first inlet to a first outlet located at the mouth end of the housing of the aerosol-generating device. The first outlet, or any outlet, of the airflow channel may be provided between the distal end and the mouth end of the device cavity.

[0052] The first outlet may be located at least about 2 mm from the distal end of the device cavity. The first outlet may be located at least about 3 mm from the distal end of the device cavity. The first outlet may be located at least about 5 mm from the distal end of the device cavity. The first outlet may be located at least about 7 mm from the distal end of the device cavity.

[0053] The distance of the first outlet from the distal end of the device cavity and the distance of the first air entry zone from the distal end of the device cavity when an article is received within the device cavity can be similar or the same. The distance of the further outlet of the air flow channel from the distal end of the device cavity and the distance of the further air entry zone from the distal end of the device cavity when an article is received within the device cavity can be similar or the same. The distance of the distal end of the air flow channel from the distal end of the device cavity and the distance of the air entry zone from the distal end of the device cavity when an article is received within the device cavity can be similar or the same.

[0054] The first outlet may be located about 25 mm or less from the distal end of the device cavity. The first outlet may be located about 3 mm to about 20 mm from the distal end of the device cavity. The first outlet may be located about 5 mm to about 18 mm from the distal end of the device cavity. The first outlet may be located about 7 mm to about 16 mm from the distal end of the device cavity. The airflow channel may not extend beyond the distal end of the device cavity.

[0055] The length of the airflow channel may be about 23 mm. The length of the airflow channel may be about 3 mm to about 100 mm. The length of the airflow channel may be about 8 mm to about 70 mm. The length of the airflow channel may be about 10 mm to about 50 mm. The length of the airflow channel may be about 12 mm to about 40 mm. The length of the airflow channel may be about 12 mm to about 40 mm. The length of the airflow channel may be about 15 mm to about 30 mm. The length of the airflow channel may be about 20 mm to about 25 mm.

[0056] When the compatible aerosol-generating article includes a first air entry zone located downstream of the rod of aerosol-forming substrate, the length of the airflow channel may be from about 8 mm to about 25 mm. The length of the airflow channel may be from about 10 mm to about 15 mm. The length of the airflow channel may be from about 11 mm to about 13 mm.

[0057] The diameter of the airflow channel may be about 0.1 mm to about 5 mm. The diameter of the airflow channel may be about 0.5 mm to about 4 mm. The diameter of the airflow channel may be about 1 mm to about 3 mm. The diameter of the airflow channel may be about 1.5 mm to about 2.5 mm. The diameters of the airflow channel and its outlet and inlet may be the same or different.

[0058] The "length" of an airflow channel may refer to how far the airflow channel extends longitudinally.

[0059] A plurality of airflow channels, each having at least one inlet and at least one outlet, may be provided within the aerosol generation device, and such a plurality of airflow channels may be evenly and circumferentially distributed around the device cavity.

[0060] The, or each, airflow channel may include a single inlet and multiple outlets, and in such embodiments, there may be one outlet corresponding to each air entry zone provided on the aerosol-generating article configured to be received within the aerosol-generating device.

[0061] As mentioned above, the aerosol-generating article according to the present invention comprises a rod of aerosol-forming substrate and a filter, or a downstream section located downstream of the rod of aerosol-forming substrate.

[0062] The aerosol-generating article further comprises an upstream section located upstream of the rod of the aerosol-generating substrate. The upstream section may comprise one or more upstream elements. In some embodiments, the upstream section may include an upstream element disposed immediately upstream of the aerosol-generating element. The upstream element may extend from the upstream end of the aerosol-generating substrate to the upstream end of the aerosol-generating article. The upstream element may abut the upstream end of the aerosol-generating article. The upstream element may be referred to as the upstream section. The aerosol-generating article may comprise an air inlet at the upstream end of the aerosol-generating article. When the aerosol-generating article comprises an upstream element, the air inlet may be provided through the upstream element. Air entering through the air inlet may pass through the aerosol-generating substrate to generate mainstream aerosol.

[0063] The porosity or permeability of the upstream section may be advantageously varied to provide a desired overall resistance to withdrawal of the aerosol-generating article.

[0064] In some embodiments, the upstream section may be formed from a material that is impermeable to air. In such embodiments, the aerosol-generating article may be configured to allow air to flow into the rod of aerosol-generating substrate via suitable venting means provided in the wrapper.

[0065] The upstream section may be made of any material suitable for use in an aerosol-generating article. For example, the upstream element may comprise a plug of material. Suitable materials for forming the upstream section include filter material, ceramic, polymeric material, cellulose acetate, cardboard, zeolite, or an aerosol-generating substrate. Preferably, the upstream section comprises a plug comprising cellulose acetate.

[0066] Where the upstream section comprises a plug of material, the downstream end of the plug of material may surround the upstream end of the aerosol-generating substrate. For example, the upstream section may comprise a plug comprising cellulose acetate that abuts the upstream end of the aerosol-generating substrate. This may advantageously help to hold the aerosol-generating substrate in place.

[0067] Where the upstream section comprises a plug of material, the downstream end of the plug of material may be spaced from the upstream end of the aerosol-generating substrate. The upstream element may comprise a plug comprising fibrous filtration material.

[0068] The upstream section can have a length of at least about 1 millimeter. For example, the upstream section may have a length of at least about 2 millimeters, at least about 4 millimeters, or at least about 6 millimeters.

[0069] The upstream section may have a length of about 15 millimeters or less. For example, the upstream section may have a length of about 12 millimeters or less, about 10 millimeters or less, or about 8 millimeters or less.

[0070] The upstream section may have a length of about 1 millimeter to about 15 millimeters. For example, the upstream section may have a length of about 2 millimeters to about 12 millimeters, about 4 millimeters to about 10 millimeters, or about 6 millimeters to about 8 millimeters.

[0071] The upstream section or element may include a hollow tubular segment.

[0072] The filter or downstream section may include a plug of filtration material and a hollow tubular segment located between the rod of the aerosol-forming substrate and the mouthpiece segment. All three elements may be longitudinally aligned. The rod of the aerosol-forming substrate may include at least the aerosol former. The hollow tubular segment may be a support segment or a cooling segment. The hollow tubular segment may be located immediately downstream of the aerosol-forming substrate, or may be located immediately downstream of the aerosol-forming substrate.

[0073] The filter or downstream section may include a plug of filtration material and an aerosol-cooling segment (or element) located between the rod of the aerosol-forming substrate and the mouthpiece segment, all three elements may be longitudinally aligned.

[0074] The mouthpiece segment may include a hollow tubular segment. The mouthpiece segment may be a hollow tubular segment. The mouthpiece segment may be a plug of filtering material.

[0075] As used herein, the term "aerosol cooling element" may refer to a component of an aerosol-generating article located downstream of an aerosol-forming substrate such that the aerosol formed by volatile compounds released from the aerosol-forming substrate during use passes through and is cooled by the aerosol cooling element before being inhaled by the user. The aerosol cooling element has a large surface area but generates a low pressure drop. The aerosol cooling element may act to cool the temperature of the aerosol flow drawn through the element by heat transfer. The components of the aerosol will interact with the aerosol cooling element and release thermal energy.

[0076] The aerosol cooling element may comprise a sheet material selected from the group consisting of metal foil, polymer sheet, and substantially non-porous paper or cardboard. In some embodiments, the aerosol cooling element may comprise a sheet material selected from the group consisting of polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), polyethylene terephthalate (PET), polylactic acid (PLA), cellulose acetate (CA), and aluminum foil.

[0077] After consumption, the aerosol-generating article is typically discarded. It may be advantageous for the elements forming the aerosol-generating article to be biodegradable. Thus, the aerosol cooling element may be advantageously formed from a biodegradable material, such as non-porous paper, or a biodegradable polymer, such as polylactic acid or the Mater-Bi® grades (a commercially available family of starch-based copolyesters). In some embodiments, the entire aerosol-generating article is biodegradable or compostable.

[0078] In some embodiments, the aerosol-generating article according to the present invention may comprise an additional support element (or support segment) disposed between the rod of the aerosol-forming substrate and the hollow tubular segment or aerosol-cooling segment (or element) in longitudinal alignment with them. More particularly, the support element (or support segment) may be provided immediately downstream of the rod and immediately upstream of the hollow tubular segment or aerosol-cooling element. The additional support element or segment may be tubular.

[0079] The wrapper of the aerosol-generating article may comprise an air-impermeable material. The wrapper of the aerosol-generating article may comprise an air-impermeable material. By providing the aerosol-generating article with an air-impermeable or air-impermeable material, it is ensured that when the upstream end of the aerosol-generating article is blocked upon insertion into the device cavity or heating chamber of the aerosol-generating device, air must be drawn through the first air entry zone to enter the aerosol-generating article. In other words, the first air entry zone may define the main and only air intake portion of the article through which air can be drawn into the article.

[0080] The expressions "air-impermeable material" or "air-impermeable material" are used throughout this specification to mean a material that does not substantially allow the passage of fluids, particularly air and smoke, through gaps or pores in the material. For example, if a wrapper is formed of a material that is impermeable to air and aerosol particles, air and aerosol particles drawn through an article cannot flow across the wrapper material. In contrast, the term "porous" is used herein to refer to a material that provides a plurality of pores or openings that allow the passage of air through the material.

[0081] By providing the wrapper with an air-impermeable material, air can only access the interior of the aerosol-generating article through a first air entry zone provided in the wrapper when the article is received in the aerosol-generating device.

[0082] The first air entry zone may be located at a (first) position along the aerosol-generating article. The first air entry zone of the aerosol-generating article may be located along the rod of the aerosol-forming substrate. The first air entry zone may be located around the rod of the aerosol-forming substrate. The first air entry zone of the aerosol-generating article may be located at a position along the rod of the aerosol-forming substrate.

[0083] The first air entry zone may be located at a position downstream of the rod of the aerosol-forming substrate.The first air entry zone may be located at or at least 1 mm downstream from the rod of the aerosol-forming substrate.

[0084] The first air entry zone of the aerosol-generating article may be located along the hollow tubular segment. The first air entry zone may be located around the hollow tubular segment. The first air entry zone of the aerosol-generating article may be located at a position along the hollow tubular segment.

[0085] The first air entry zone of the aerosol-generating article may be located along the support segment. The first air entry zone may be located around the support segment. The first air entry zone of the aerosol-generating article may be located at a position along the support segment. The support segment may be a hollow support segment.

[0086] The aerosol-generating article may extend between an upstream end and a downstream end. The downstream end of the article may coincide with the downstream end of the rod of aerosol-forming substrate. In other words, the downstream end of the rod of aerosol-forming substrate may define the downstream end of the aerosol-generating article.

[0087] The first air entry zone may be located at least about 2 mm downstream from the upstream end of the rod of the aerosol-forming substrate. The first air entry zone may be located at least about 3 mm downstream from the upstream end of the rod of the aerosol-forming substrate. The first air entry zone may be located at least about 4 mm downstream from the upstream end of the rod of the aerosol-forming substrate. The first air entry zone may be located at least about 5 mm downstream from the upstream end of the rod of the aerosol-forming substrate. The first air entry zone may be located at least about 6 mm downstream from the upstream end of the rod of the aerosol-forming substrate. The first air entry zone may be located at least about 7 mm downstream from the upstream end of the rod of the aerosol-forming substrate. The first air entry zone may be located at least about 8 mm downstream from the upstream end of the rod of the aerosol-forming substrate. The first air entry zone may be located at least about 9 mm downstream from the upstream end of the rod of the aerosol-forming substrate. The first air entry zone may be located at least about 10 mm downstream from the upstream end of the rod of the aerosol-forming substrate. The first air entry zone may be located at least about 12 mm downstream of the upstream end of the rod of the aerosol-forming substrate.

[0088] The first air entry zone may be located approximately 20 mm or less downstream of the upstream end of the rod of the aerosol-forming substrate. The first air entry zone may be located approximately 15 mm or less downstream of the upstream end of the rod of the aerosol-forming substrate. The first air entry zone may be located approximately 14 mm or less downstream of the upstream end of the rod of the aerosol-forming substrate. The first air entry zone may be located approximately 13 mm or less downstream of the upstream end of the rod of the aerosol-forming substrate. The first air entry zone may be located approximately 12 mm or less downstream of the upstream end of the rod of the aerosol-forming substrate. The first air entry zone may be located approximately 10 mm or less downstream of the upstream end of the rod of the aerosol-forming substrate. The first air entry zone may be located approximately 9 mm or less downstream of the upstream end of the rod of the aerosol-forming substrate. The first air entry zone may be located approximately 8 mm or less downstream of the upstream end of the rod of the aerosol-forming substrate. The first air entry zone may be located no more than about 6 mm downstream of the upstream end of the rod of the aerosol-forming substrate.The first air entry zone may be located no more than about 5 mm downstream of the upstream end of the rod of the aerosol-forming substrate.

[0089] The first air entry zone may be located about 2 mm to about 20 mm downstream from the upstream end of the rod of the aerosol-forming substrate. The first air entry zone may be located about 3 mm to about 15 mm downstream from the upstream end of the rod of the aerosol-forming substrate. The first air entry zone may be located about 4 mm to about 12 mm downstream from the upstream end of the rod of the aerosol-forming substrate.

[0090] The first air entry zone may be located about 2 mm to about 15 mm downstream from the upstream end of the rod of the aerosol-forming substrate. The first air entry zone may be located about 3 mm to about 12 mm downstream from the upstream end of the rod of the aerosol-forming substrate. The first air entry zone may be located about 5 mm to about 10 mm downstream from the upstream end of the rod of the aerosol-forming substrate.

[0091] The first air entry zone may be located about 2 mm to about 12 mm downstream from the upstream end of the rod of the aerosol-forming substrate. The first air entry zone may be located about 3 mm to about 10 mm downstream from the upstream end of the rod of the aerosol-forming substrate. The first air entry zone may be located about 5 mm to about 8 mm downstream from the upstream end of the rod of the aerosol-forming substrate.

[0092] The first air entry zone may be located about 2 mm to about 10 mm downstream from the upstream end of the rod of the aerosol-forming substrate. The first air entry zone may be located about 3 mm to about 9 mm downstream from the upstream end of the rod of the aerosol-forming substrate. The first air entry zone may be located about 5 mm to about 8 mm downstream from the upstream end of the rod of the aerosol-forming substrate.

[0093] The first air entry zone may be located about 2 mm to about 8 mm downstream from the upstream end of the rod of the aerosol-forming substrate. The first air entry zone may be located about 2 mm to about 6 mm downstream from the upstream end of the rod of the aerosol-forming substrate. The first air entry zone may be located about 2 mm to about 5 mm downstream from the upstream end of the rod of the aerosol-forming substrate.

[0094] The first air entry zone may be located about 10 mm to about 20 mm downstream from the upstream end of the rod of the aerosol-forming substrate.The first air entry zone may be located about 12 mm to about 15 mm downstream from the upstream end of the rod of the aerosol-forming substrate.

[0095] The first air entry zone may be located along the upstream half of the rod of the aerosol-forming substrate. By locating the first air entry zone along the upstream half of the rod of the aerosol-forming substrate, air drawn through the first air entry zone can be drawn through a substantial length of the rod of the aerosol-forming substrate in order to optimize aerosol generation and make efficient use of the aerosol-forming substrate.

[0096] The first air entry zone may be located along the downstream half of the rod of the aerosol-forming substrate. The first air entry zone may be located along the upstream half of the hollow tubular segment. The first air entry zone may be located along the upstream half of the support segment. The first air entry zone may be located along the downstream half of the hollow tubular segment. The first air entry zone may be located along the downstream half of the support segment.

[0097] Throughout this specification, when it is said that an air entry zone is or can be located along a particular component of the aerosol-generating article, this refers to the fact that the air entry zone is located on a portion of the wrapper that covers that component of the aerosol-generating article. For example, when it is said that the air entry zone is located along the rod of the aerosol-forming substrate, this refers to the fact that the air entry zone is located on a portion of the wrapper that covers the rod of the aerosol-forming substrate.

[0098] The term "upstream half" refers to the region or portion of an element between the upstream end of the element and the midpoint of the element. The term "downstream half" refers to the region or portion of an element between the downstream end of the element and the midpoint of the element.

[0099] An aerosol-generating article may be provided with additional air entry zones to provide additional functionality to the first air entry zone. The aerosol-generating article may include a second air entry zone located on the wrapper. Such a second air entry zone may be configured to provide ventilation for the aerosol-generating article within the device during use as a ventilation zone, with the first air entry zone functioning as an air intake zone for the article. Additionally, air entry zones may be provided to provide additional ventilation for the article during normal and compatible use.

[0100] The second air entry zone may be located at a (second) position along the aerosol-generating article. The second air entry zone may be located on the wrapper at a position downstream from the first air entry zone. The second air entry zone may be provided at a location along the same component of the aerosol-generating article as the first air entry zone. For example, if the first air entry zone is provided along the rod of the aerosol-forming substrate, the second air entry zone may be provided along the rod of the aerosol-forming substrate at a position downstream from the first air entry zone.

[0101] The second air entry zone may be located downstream of the rod of the aerosol-forming substrate. The second air entry zone may be located downstream of the downstream end of the rod of the aerosol-forming substrate. The second air entry zone may be located along the filter or downstream section of the aerosol-generating article. The second air entry zone may be located along the hollow tubular segment. The second air entry zone may be located along the support segment.

[0102] The second air entry zone may be located at least about 1 mm downstream from the rod of the aerosol-forming substrate. That is, the second air entry zone may be located at least 1 mm downstream from the downstream end of the rod of the aerosol-forming substrate. The second air entry zone may be located at least about 2 mm downstream from the rod of the aerosol-forming substrate. The second air entry zone may be located at least about 3 mm downstream from the rod of the aerosol-forming substrate.

[0103] The second air entry zone may be located about 8 mm or less downstream from the rod of the aerosol-forming substrate. The second air entry zone may be located about 7 mm or less downstream from the rod of the aerosol-forming substrate. The second air entry zone may be located about 6 mm or less downstream from the rod of the aerosol-forming substrate.

[0104] The second air entry zone may be located about 1 mm to about 8 mm downstream from the rod of the aerosol-forming substrate. The second air entry zone may be located about 2 mm to about 7 mm downstream from the rod of the aerosol-forming substrate. The second air entry zone may be located about 2 mm to about 6 mm downstream from the rod of the aerosol-forming substrate. The second air entry zone may be located about 3 mm to about 6 mm downstream from the rod of the aerosol-forming substrate.

[0105] The second air entry zone may be located at least about 1 mm downstream from the upstream end of the hollow tubular segment. The second air entry zone may be located at least about 2 mm downstream from the upstream end of the hollow tubular segment. The second air entry zone may be located at least about 3 mm downstream from the upstream end of the hollow tubular segment.

[0106] The second air entry zone may be located approximately 8 mm or less downstream of the upstream end of the hollow tubular segment. The second air entry zone may be located approximately 7 mm or less downstream of the upstream end of the hollow tubular segment. The second air entry zone may be located approximately 6 mm or less downstream of the upstream end of the hollow tubular segment.

[0107] The second air entry zone may be located about 1 mm to about 8 mm downstream from the upstream end of the hollow tubular segment. The second air entry zone may be located about 2 mm to about 7 mm downstream from the upstream end of the hollow tubular segment. The second air entry zone may be located about 2 mm to about 6 mm downstream from the upstream end of the hollow tubular segment. The second air entry zone may be located about 3 mm to about 6 mm downstream from the upstream end of the hollow tubular segment.

[0108] The second air entry zone may be located at least about 1 mm downstream from the upstream end of the support segment. The second air entry zone may be located at least about 2 mm downstream from the upstream end of the support segment. The second air entry zone may be located at least about 3 mm downstream from the upstream end of the support segment.

[0109] The second air admission zone may be located approximately 8 mm or less downstream from the upstream end of the support segment. The second air admission zone may be located approximately 7 mm or less downstream from the upstream end of the support segment. The second air admission zone may be located approximately 6 mm or less downstream from the upstream end of the support segment.

[0110] The second air entry zone may be located about 1 mm to about 8 mm downstream from the upstream end of the support segment. The second air entry zone may be located about 2 mm to about 7 mm downstream from the upstream end of the support segment. The second air entry zone may be located about 2 mm to about 6 mm downstream from the upstream end of the support segment. The second air entry zone may be located about 3 mm to about 6 mm downstream from the upstream end of the support segment.

[0111] As described above, the second air entry zone may be located along the rod of the aerosol-forming substrate. The second air entry zone may be located at least about 3.5 mm downstream from the upstream end of the rod of the aerosol-forming substrate. The second air entry zone may be located at least about 4 mm downstream from the upstream end of the rod of the aerosol-forming substrate. The second air entry zone may be located at least about 6.5 mm downstream from the upstream end of the rod of the aerosol-forming substrate.

[0112] The second air entry zone may be located about 20 mm or less downstream of the upstream end of the rod of the aerosol-forming substrate. The second air entry zone may be located about 16 mm or less downstream of the upstream end of the rod of the aerosol-forming substrate. The second air entry zone may be located about 12 mm or less downstream of the upstream end of the rod of the aerosol-forming substrate.

[0113] The second air entry zone may be located about 3.5 mm to about 20 mm downstream from the upstream end of the rod of the aerosol-forming substrate. The second air entry zone may be located about 4 mm to about 16 mm downstream from the upstream end of the rod of the aerosol-forming substrate. The second air entry zone may be located about 6.5 mm to about 12 mm downstream from the upstream end of the rod of the aerosol-forming substrate.

[0114] The second air entry zone may be located at least about 1.5 mm downstream from the first air entry zone. The second air entry zone may be located at least about 2 mm downstream from the first air entry zone. The second air entry zone may be located at least about 3 mm downstream from the first air entry zone.

[0115] The second air entrance zone may be located at least about 10 mm downstream from the first air entrance zone. The second air entrance zone may be located at least about 12 mm downstream from the first air entrance zone. In such embodiments, the second air entrance zone may be located downstream from the rod of the aerosol-forming substrate.

[0116] The second air admission zone may be located approximately 20 mm or less downstream from the first air admission zone. The second air admission zone may be located approximately 18 mm or less downstream from the first air admission zone. The second air admission zone may be located approximately 16 mm or less downstream from the first air admission zone.

[0117] The second air entry zone may be located about 1.5 mm to about 20 mm downstream from the first air entry zone. The second air entry zone may be located about 2 mm to about 18 mm downstream from the first air entry zone. The second air entry zone may be located about 3 mm to about 16 mm downstream from the first air entry zone.

[0118] The second air entry zone may be located along the upstream half of the rod of the aerosol-forming substrate. The second air entry zone may be located along the downstream half of the rod of the aerosol-forming substrate. The second air entry zone may be located along the upstream half of the hollow tubular segment. The second air entry zone may be located along the upstream half of the support segment. The second air entry zone may be located along the downstream half of the hollow tubular segment. The second air entry zone may be located along the downstream half of the support segment.

[0119] The air entry zone may include one or more rows of openings or perforations through the wrapper of the aerosol-generating article. The openings or perforations in the air entry zone may extend through a filter or downstream section of the aerosol-generating article. The openings or perforations in the air entry zone may extend through a peripheral wall of a hollow tubular segment of the article. The openings or perforations in the air entry zone may extend through a peripheral wall of a support segment of the article, particularly if the support segment is hollow.

[0120] The air entry zone may include only one row of apertures or perforations. The row of apertures or perforations may include 8 to 30 apertures or perforations. The row of apertures or perforations may include 10 to 20 apertures or perforations. The air entry zone may surround the aerosol-generating article. The air entry zone may surround the rod of the aerosol-forming substrate. The air entry zone may surround the hollow tubular segment. The air entry zone may surround the support segment.

[0121] The perforations in the air entry zone may be of uniform size. Alternatively, the perforations may vary in size. By varying the number and size of the perforations, it is possible to adjust the amount of outside air that enters the hollow tubular segment when a consumer draws on the mouthpiece of the aerosol-generating article during use. This advantageously makes it possible to adjust the ventilation level or air intake level of the aerosol-generating article. Preferably, the perforations are circular.

[0122] The air-entry perforations can be formed using any suitable technique, such as by laser techniques, mechanical perforation of the hollow tubular or support segment as part of the aerosol-generating article, or pre-perforation of the hollow tubular or support segment before it is combined with other elements to form the aerosol-generating article. Preferably, the perforations are formed by online laser perforation.

[0123] In addition, the inventors have discovered that in an aerosol-generating article according to the present invention, the cooling and dilution effect caused by the introduction of ventilation air at locations along the conduit defined by the hollow tubular segments described above has a surprising reducing effect on the generation and delivery of phenol-containing species.

[0124] The air entry zone or vent zone may include one or more rows of perforations formed through the peripheral wall of the hollow tubular segment. As noted above, the second air entry zone may be a vent zone. Preferably, the vent zone includes only one row of perforations. This is understood to be advantageous in that it may further enhance aerosol nucleation by condensing the cooling effect provided by the vent across the short portion of the cavity defined by the hollow tubular segment. This is because the faster and more dramatic cooling of the volatilized species stream is expected to be particularly favorable to the formation of new nuclei of aerosol particles.

[0125] Preferably, the one or more rows of perforations are circumferentially disposed about the wall of the hollow tube. When the ventilation zone comprises two or more rows of perforations formed through the peripheral wall of the hollow tubular segment, the rows are longitudinally spaced from one another along the hollow tubular segment.

[0126] The radius of the air entry perforations or openings may be at least about 0.05 mm. The radius of the air entry perforations or openings may be at least about 0.06 mm. The radius of the air entry perforations or openings may be at least about 0.1 mm. The radius of the air entry perforations may be between about 0.06 mm and about 0.1 mm.

[0127] The equivalent diameter of at least one of the vent perforations or air entry perforations is preferably at least about 100 micrometers. Preferably, the equivalent diameter of at least one of the vent perforations is at least about 150 micrometers. Even more preferably, the equivalent diameter of at least one of the vent perforations is at least about 200 micrometers. Additionally or alternatively, the equivalent diameter of at least one of the vent perforations is preferably less than about 500 micrometers. More preferably, the equivalent diameter of at least one of the vent perforations is less than about 450 micrometers. Even more preferably, the equivalent diameter of at least one of the vent perforations is less than about 400 micrometers. The term "equivalent diameter" is used herein to mean the diameter of a circle having the same surface area as the cross-section of the vent perforation. The cross-section of the vent perforation may have any suitable shape. However, circular vent perforations are preferred.

[0128] The ventilation or air entry perforations may be of uniform size. Alternatively, the ventilation perforations may vary in size. By varying the number and size of the ventilation perforations, it is possible to adjust the amount of outside air that enters the hollow tubular segment when a consumer draws on the mouthpiece of the aerosol-generating article during use. This advantageously allows the ventilation level of the aerosol-generating article to be adjusted.

[0129] The air entry zone may comprise a substantially porous portion of the wrapper of the aerosol-generating article. Such a porous portion may be defined in the air-impermeable or air-impermeable wrapper of the aerosol-generating article, or may be defined by a different material that forms part of the wrapper of the aerosol-generating article. Such a porous portion may be defined by a porosity pattern defined in the wrapper. Such a porous portion may define a first or second air entry zone. As such, the first or second air entry zone may have the porosity characteristics of such a porous portion.

[0130] Such porous portions of the wrapper may have a relatively high porosity relative to the remainder of the wrapper of the aerosol-generating article. The porosity of such porous portions may be at least about 3000 Coresta units (CU). The porosity of such porous portions may be at least about 5000 Coresta units (CU). The porosity of such porous portions may be less than about 25000 Coresta units (CU). The porosity of such porous portions may be less than about 20000 Coresta units (CU). The porosity of such porous portions may be between about 3000 CU and about 25000 CU. The porosity of such porous portions may be between about 5000 CU and about 20000 CU.

[0131] The width of the air entry zone (first, second, or any air entry zone) may be at least about 1 mm. The width of the air entry zone may be at least about 3 mm. The width of the air entry zone may be at least about 5 mm. The "width" of the air entry zone refers to the sizing of the air entry zone along the axial or longitudinal axis of the aerosol-generating article. This "width" of the air entry zone may also be referred to as the "length" of the air entry zone.

[0132] The width of the first air entry zone may be greater than the width of the second air entry zone, such that the first air entry zone serves as the primary air intake for the aerosol-generating article when received within a compatible aerosol-generating device, and the second or subsequent air entry zone may serve as a secondary air intake or ventilation zone.

[0133] Such a relatively wide air entry zone may be formed from a porous portion of the wrapper having a relatively high void volume, multiple rows of perforations, or relatively wide perforations (as discussed above).

[0134] By providing a wider air entry zone, such as the first air entry zone, there is a greater surface area of ​​the first air entry that overlaps or aligns with the outlet of the airflow channel of the aerosol generating device. This therefore reliably ensures that fluid communication is established between the exterior of the aerosol generating device and the interior of the aerosol-generating article received within the device so that the article can be properly consumed by a consumer. Having a relatively wide air entry zone can be a source of inaccuracies in the manufacture of the air entry zone, which can affect the positioning of the air entry zone relative to the outlet of the airflow channel of the device.

[0135] The air entry zone may completely or partially surround the aerosol-generating article. The air entry zone may be located around the aerosol-generating article.

[0136] The aerosol-generating article may comprise a first air entry zone and a second air entry zone located along the rod of the aerosol-forming substrate. The aerosol-generating article may comprise a first air entry zone located along the rod of the aerosol-forming substrate and a second air entry zone located downstream of the rod of the aerosol-forming substrate. The aerosol-generating article may comprise a first air entry zone located along the rod of the aerosol-forming substrate and a second air entry zone located along the hollow tubular segment. The aerosol-generating article may comprise a first air entry zone located along the rod of the aerosol-forming substrate and a second air entry zone located along the support segment.

[0137] Each air entry zone may provide or allow a certain level of air ingress into the interior of the aerosol-generating article. The level of air ingress may refer to the amount of fluid that can enter through the air entry zone to enter the interior of the aerosol-generating article. The level of air ingress may be expressed in terms of the volume (in cubic millimeters) of air that can enter through the air entry zone over a certain period of time (expressed in seconds). The level of air ingress may be expressed in terms of mass flow rate (grams or kilograms per second) or volumetric flow rate (milliliters or liters per second).

[0138] The level of air ingress into the interior of the aerosol-generating article through the first air entry zone may be configured to be greater than the level of air ingress into the interior of the aerosol-generating article through the second air entry zone, ensuring that when the aerosol-generating article is received in an aerosol generating device, an adequate amount of air flows through the first air entry zone during use to function as the primary air intake zone for the article, and the second air entry zone can provide ventilation for the article.

[0139] The level of air ingress through the air entry zone may be defined as a volumetric flow rate. The level of air ingress, i.e., the level of air ingress into the interior of the aerosol-generating article through the first air entry zone, may be at least about 10 percent greater than the level of air ingress (volumetric flow rate) into the interior of the aerosol-generating article through the second air entry zone. The level of air ingress, i.e., the level of air ingress into the interior of the aerosol-generating article through the first air entry zone, may be at least about 20 percent greater than the level of air ingress (volumetric flow rate) into the interior of the aerosol-generating article through the second air entry zone. The level of air ingress, i.e., the level of air ingress into the interior of the aerosol-generating article through the first air entry zone, may be at least about 30 percent greater than the level of air ingress (volumetric flow rate) into the interior of the aerosol-generating article through the second air entry zone.

[0140] The level of air ingress, i.e., the level of air ingress into the interior of the aerosol-generating article through the first air entry zone, may be less than about 300 percent greater than the level (volumetric flow rate) of air ingress into the interior of the aerosol-generating article through the second air entry zone. The level of air ingress, i.e., the level of air ingress into the interior of the aerosol-generating article through the first air entry zone, may be less than about 200 percent greater than the level (volumetric flow rate) of air ingress into the interior of the aerosol-generating article through the second air entry zone. The level of air ingress, i.e., the level of air ingress into the interior of the aerosol-generating article through the first air entry zone, may be less than about 100 percent greater than the level (volumetric flow rate) of air ingress into the interior of the aerosol-generating article through the second air entry zone. The level of air ingress, i.e., the level of air ingress into the interior of the aerosol-generating article through the first air entry zone, may be less than about 90 percent greater than the level (volumetric flow rate) of air ingress into the interior of the aerosol-generating article through the second air entry zone. The level of air ingress, i.e., the level of air ingress into the interior of the aerosol-generating article through the first air entry zone, may be less than about 75 percent greater than the level (volumetric flow rate) of air ingress into the interior of the aerosol-generating article through the second air entry zone. The level of air ingress, i.e., the level of air ingress into the interior of the aerosol-generating article through the first air entry zone, may be less than about 60 percent greater than the level (volumetric flow rate) of air ingress into the interior of the aerosol-generating article through the second air entry zone.

[0141] During a certain period of time, from a particular volume of air entering the aerosol-generating device through an airflow channel or multiple airflow channels, a first proportion of such air intake may enter the interior of the aerosol-generating article through a first air entry zone, and a second proportion of such air intake may enter the interior of the aerosol-generating article through a second air entry zone. For example, during a certain period of time T, a volume V of air may enter the aerosol-generating device, then a first proportion of V (represented as a proportion of V) may enter the interior of the aerosol-generating article through the first air entry zone, and a second proportion of V may enter the interior of the aerosol-generating article through the second air entry zone.

[0142] During a certain period of time, of the total volume of air intake entering the aerosol-generating device, at least about 50 percent of this total volume may enter the interior of the aerosol-generating article through the first air entry zone. During a certain period of time, of the total volume of air intake entering the aerosol-generating device, at least about 55 percent of this total volume may enter the interior of the aerosol-generating article through the first air entry zone. During a certain period of time, of the total volume of air intake entering the aerosol-generating device, at least about 60 percent of this total volume may enter the interior of the aerosol-generating article through the first air entry zone. During a certain period of time, of the total volume of air intake entering the aerosol-generating device, at least about 70 percent of this total volume may enter the interior of the aerosol-generating article through the first air entry zone. During a certain period of time, of the total volume of air intake entering the aerosol-generating device, at least about 75 percent of this total volume may enter the interior of the aerosol-generating article through the first air entry zone.

[0143] During a given period, of the total volume of air intake entering the aerosol-generating device, less than about 50 percent of this total volume may enter the interior of the aerosol-generating article through the second air entry zone. During a given period, of the total volume of air intake entering the aerosol-generating device, less than about 45 percent of this total volume may enter the interior of the aerosol-generating article through the second air entry zone. During a given period, of the total volume of air intake entering the aerosol-generating device, less than about 40 percent of this total volume may enter the interior of the aerosol-generating article through the second air entry zone. During a given period, of the total volume of air intake entering the aerosol-generating device, less than about 30 percent of this total volume may enter the interior of the aerosol-generating article through the second air entry zone. During a given period, of the total volume of air intake entering the aerosol-generating device, less than about 25 percent of this total volume may enter the interior of the aerosol-generating article through the second air entry zone.

[0144] During a certain period of time, of the total volume of air intake entering the aerosol-generating device, approximately 50 percent of such total volume may enter the interior of the aerosol-generating article through the first air entry zone, and approximately 50 percent of such total volume may enter the interior of the aerosol-generating article through the second air entry zone.

[0145] During a certain period of time, of the total volume of air intake entering the aerosol-generating device, approximately 55 percent of such total volume may enter the interior of the aerosol-generating article through the first air entry zone, and approximately 45 percent of such total volume may enter the interior of the aerosol-generating article through the second air entry zone.

[0146] During a certain period of time, of the total volume of air intake entering the aerosol-generating device, approximately 60 percent of such total volume may enter the interior of the aerosol-generating article through the first air entry zone, and approximately 40 percent of such total volume may enter the interior of the aerosol-generating article through the second air entry zone.

[0147] During a certain period of time, of the total volume of air intake entering the aerosol-generating device, approximately 70 percent of such total volume may enter the interior of the aerosol-generating article through the first air entry zone, and approximately 30 percent of such total volume may enter the interior of the aerosol-generating article through the second air entry zone.

[0148] During a certain period of time, of the total volume of air intake entering the aerosol-generating device, approximately 75 percent of such total volume may enter the interior of the aerosol-generating article through the first air entry zone, and approximately 25 percent of such total volume may enter the interior of the aerosol-generating article through the second air entry zone.

[0149] Similarly, a particular volumetric flow rate may flow through the airflow channel or channels of the aerosol-generating device before the air exits the airflow channel toward the aerosol-generating article. From this intake volumetric flow rate (or the airflow channel volumetric flow rate present in the pre-exit airflow channel), a first percentage of this intake volumetric flow rate may flow through a first air entry zone, and a second percentage of this intake volumetric flow rate may flow through a second air entry zone. For example, a volumetric flow rate VF may flow through the airflow channel, and then a first percentage of VF (expressed as a percentage of VF) may flow through the first air entry zone, and a second percentage of VF may flow through the second air entry zone.

[0150] For an intake volumetric flow rate that flows through the airflow channel of the aerosol generation device, at least about 50 percent of such intake volumetric flow rate may flow through the first air entry zone. For an intake volumetric flow rate that flows through the airflow channel of the aerosol generation device, at least about 55 percent of such intake volumetric flow rate may flow through the first air entry zone. For an intake volumetric flow rate that flows through the airflow channel of the aerosol generation device, at least about 60 percent of such intake volumetric flow rate may flow through the first air entry zone. For an intake volumetric flow rate that flows through the airflow channel of the aerosol generation device, at least about 70 percent of such intake volumetric flow rate may flow through the first air entry zone. For an intake volumetric flow rate that flows through the airflow channel of the aerosol generation device, at least about 75 percent of such intake volumetric flow rate may flow through the first air entry zone.

[0151] For an intake volumetric flow rate that flows through the airflow channel of the aerosol generation device, less than about 50 percent of such intake volumetric flow rate may flow through the second air entry zone. For an intake volumetric flow rate that flows through the airflow channel of the aerosol generation device, less than about 45 percent of such intake volumetric flow rate may flow through the second air entry zone. For an intake volumetric flow rate that flows through the airflow channel of the aerosol generation device, less than about 40 percent of such intake volumetric flow rate may flow through the second air entry zone. For an intake volumetric flow rate that flows through the airflow channel of the aerosol generation device, less than about 30 percent of such intake volumetric flow rate may flow through the second air entry zone. For an intake volumetric flow rate that flows through the airflow channel of the aerosol generation device, less than about 25 percent of such intake volumetric flow rate may flow through the second air entry zone.

[0152] For an intake volumetric flow rate through the airflow channel of the aerosol generation device, about 50 percent of such intake volumetric flow rate may flow through the first air entry zone and about 50 percent of such intake volumetric flow rate may flow through the second air entry zone.

[0153] For an intake volumetric flow rate through the airflow channel of the aerosol generation device, approximately 55 percent of such intake volumetric flow rate may flow through the first air entry zone and approximately 45 percent of such intake volumetric flow rate may flow through the second air entry zone.

[0154] For an intake volumetric flow rate through the airflow channel of the aerosol generating device, about 60 percent of such intake volumetric flow rate may flow through the first air entry zone and about 40 percent of such intake volumetric flow rate may flow through the second air entry zone.

[0155] For an intake volumetric flow rate through the airflow channel of the aerosol generating device, about 70 percent of such intake volumetric flow rate may flow through the first air entry zone and about 30 percent of such intake volumetric flow rate may flow through the second air entry zone.

[0156] For an intake volumetric flow rate through the airflow channel of the aerosol generating device, about 75 percent of such intake volumetric flow rate may flow through the first air entry zone and about 25 percent of such intake volumetric flow rate may flow through the second air entry zone.

[0157] The term "ventilation level" may be used throughout this specification to refer to the volume ratio between the airflow entering the aerosol-generating article through the air entry zone (air entry airflow) and the airflow exiting the aerosol-generating article through the mouth end or downstream end. The greater the ventilating level, the greater the dilution of the aerosol stream delivered to the consumer. The ventilating level is measured on the aerosol-generating article itself, i.e., without inserting the aerosol-generating article into a suitable aerosol-generating device adapted to heat the aerosol-forming substrate.

[0158] The level of ventilation provided by the first air entry zone, if present, may be measured by drawing air from the mouth end of the aerosol-generating article, blocking all other air entry zones, so that air enters the aerosol-generating article through the forward or upstream end of the aerosol-generating article and the first air entry zone. The level of ventilation provided by the first air entry zone may be defined as the ratio between the flow rate of air (airflow) entering the aerosol-generating article through the first air entry zone and the flow rate of air exiting the aerosol-generating article at the mouth end.

[0159] The level of ventilation provided by the second air entry zone, if present, may be measured by drawing air from the mouth end of the aerosol-generating article, blocking all other air entry zones, so that air enters the aerosol-generating article through the forward or upstream end of the aerosol-generating article and the second air entry zone. The level of ventilation provided by the second air entry zone may be defined as the ratio between the flow rate of air (airflow) entering the aerosol-generating article through the second air entry zone and the flow rate of air exiting the aerosol-generating article at the mouth end.

[0160] The total airflow level of an aerosol-generating article can be measured by drawing air from the mouth end of the aerosol-generating article so that any air entry zones present in the aerosol-generating article are not blocked and air enters the aerosol-generating article through the forward or upstream end and the air entry zones. The total airflow level of an aerosol-generating article can be defined as the ratio between the sum of the air flow rates entering the aerosol-generating article through each of the air entry zones and the air flow rate exiting the aerosol-generating article at the mouth end.

[0161] The level of ventilation provided by the first air entry zone to the aerosol-generating article may be at least about 10 percent. The level of ventilation provided by the first air entry zone may be at least about 20 percent. The level of ventilation provided by the first air entry zone may be at least about 25 percent. The level of ventilation provided by the first air entry zone may be at least about 50 percent. The level of ventilation provided by the first air entry zone may be at least about 75 percent.

[0162] The level of ventilation provided by the second air entry zone to the aerosol-generating article may be at least about 10 percent. The level of ventilation provided by the second air entry zone may be at least about 20 percent. The level of ventilation provided by the second air entry zone may be at least about 25 percent. The level of ventilation provided by the second air entry zone may be at least about 50 percent. The level of ventilation provided by the second air entry zone may be at least about 75 percent.

[0163] The ventilation level provided by the first air entry zone or the second air entry zone may be about 75 percent or less. The ventilation level provided by the first air entry zone or the second air entry zone may be about 60 percent or less. The ventilation level provided by the first air entry zone or the second air entry zone may be about 50 percent or less.

[0164] The ventilation level provided by the first air entry zone or by the second air entry zone may be from about 10 percent to about 75 percent. The ventilation level provided by the first air entry zone or by the second air entry zone may be from about 30 percent to about 60 percent.

[0165] Aerosol-generating articles may typically have a total breathability level of at least about 10 percent, preferably at least about 20 percent.

[0166] The aerosol-generating article may have a total breathability level of at least about 20 percent, or at least about 25 percent, or at least about 30 percent. The aerosol-generating article may have a total breathability level of at least about 35 percent. The aerosol-generating article may have a total breathability level of less than about 60 percent. The aerosol-generating article may have a total breathability level of less than about 50 percent, or less than about 40 percent. The aerosol-generating article may have a total breathability level of between about 25 percent and about 60 percent.

[0167] The aerosol-generating article may have a total breathability level of about 10 percent to about 90 percent. The aerosol-generating article may have a total breathability level of about 20 percent to about 80 percent. The aerosol-generating article may have a total breathability level of about 25 percent to about 60 percent. The aerosol-generating article may have a total breathability level of about 30 percent to about 50 percent. The aerosol-generating article may have a total breathability level of about 30 percent to about 40 percent.

[0168] The aerosol-generating article may have a total ventilation level of about 28 percent to about 42 percent. The aerosol-generating article may have a ventilation level of about 35 percent. The inventors surprisingly found that the dilution effect on the aerosol (which can be assessed, inter alia, by measuring the effect on the delivery of glycerin contained in the aerosol-forming substrate as an aerosol former) is advantageously minimized when the ventilation level is about 30 percent to about 50 percent. In particular, ventilation levels of about 35 percent to about 42 percent have been found to lead to particularly satisfactory glycerin delivery values. At the same time, the degree of nucleation, and consequently, the delivery of nicotine and the aerosol former (e.g., glycerol), is enhanced.

[0169] The first air entry zone may function as the first or primary air intake zone, and the second air entry zone may function as a ventilation zone for the aerosol-generating article, since the first entry zone is configured to be the primary intake point for air when the aerosol-generating article is positioned within the device cavity and may be configured to admit the highest level of air compared to any other air entry zones provided on the article wrapper.

[0170] The first air entry zone, as described above, ensures compatibility between the aerosol-generating article and the aerosol-generating device by defining a primary air intake zone for the article, and the second air entry zone provides ventilation to the aerosol-generating article during normal use when the aerosol-generating article is received within the device. All air entry zones may be located within the device cavity or heating chamber of the aerosol-generating device during normal use. This prevents inadvertent blocking of any of the air entry zones with hands or lips during normal use, which may adversely affect the user's experience because the article may not be well ventilated.

[0171] Providing ventilation to an aerosol-generating article during normal use has advantages. Without wishing to be bound by theory, it has been found that the temperature reduction caused by admitting cooler ambient air into the hollow tubular segment through the ventilation zone can have a beneficial effect on aerosol particle nucleation and growth.

[0172] In this scenario (when the scenario is further complicated by fusion phenomena), the temperature and rate of cooling may play an important role in determining how the system responds. In general, because the nucleation process is typically nonlinear, different cooling rates may lead to significantly different temperature behaviors with respect to the formation of the liquid phase (droplets). Without wishing to be bound by theory, it is hypothesized that cooling can cause a rapid increase in the number of condensed droplets, followed by a short-term, strong increase in this growth (nucleation burst). This nucleation burst appears to be more pronounced at lower temperatures. Furthermore, it appears that a faster cooling rate may favor the onset of early nucleation. In contrast, a decrease in the cooling rate appears to have a favorable effect on the final size that the aerosol droplets ultimately reach.

[0173] Thus, the rapid cooling induced by admitting ambient air into the hollow tubular segment through the ventilation zone can be used to favor favorable nucleation and growth of aerosol droplets. At the same time, however, admitting ambient air into the hollow tubular segment has the direct drawback of diluting the aerosol stream delivered to the consumer.

[0174] Additionally, it has been discovered that in aerosol-generating articles according to the present invention, the cooling and dilution effect caused by the introduction of ventilation air at locations along the conduit defined by the hollow tubular segments described above has a surprising reducing effect on the generation and delivery of phenol-containing species.

[0175] This is understood to be advantageous in that aerosol nucleation may potentially be further enhanced by condensing the cooling effect provided by the ventilation across the short section of the cavity defined by the hollow tubular segment, as the faster and more dramatic cooling of the stream of species volatilized from the aerosol-forming substrate is expected to be particularly favorable to the formation of new nuclei of aerosol particles.

[0176] The rod of aerosol-forming substrate preferably has an outer diameter approximately equal to the outer diameter of the aerosol-generating article.

[0177] The aerosol-forming substrate rod preferably has an outer diameter of at least about 4 millimeters (mm). The aerosol-forming substrate rod may have an outer diameter of at least about 5 millimeters. The aerosol-forming substrate rod may have an outer diameter of about 5 millimeters to about 12 millimeters, for example, about 5 millimeters to about 10 millimeters, or about 6 millimeters to about 8 millimeters. In a preferred embodiment, the aerosol-forming substrate rod has an outer diameter of 7.2 millimeters ±10 percent.

[0178] The rod of the aerosol-forming substrate may have a length of about 5 millimeters to about 100 mm. The rod of the aerosol-forming substrate preferably has a length of at least about 5 millimeters, and more preferably has a length of at least about 7 millimeters. Additionally or alternatively, the rod of the aerosol-forming substrate preferably has a length of less than about 80 millimeters, more preferably has a length of less than about 65 millimeters, and even more preferably has a length of less than about 50 millimeters. In a particularly preferred embodiment, the rod of the aerosol-forming substrate has a length of less than about 35 millimeters, more preferably has a length of less than 25 millimeters, and even more preferably has a length of less than about 20 millimeters. In one embodiment, the rod of the aerosol-forming substrate may have a length of about 10 millimeters. In one preferred embodiment, the rod of the aerosol-forming substrate has a length of about 12 millimeters.

[0179] The rod of aerosol-forming substrate preferably has a substantially uniform cross section along the length of the rod, and it is particularly preferred that the rod of aerosol-forming substrate has a substantially circular cross section.

[0180] In a preferred embodiment, the aerosol-forming substrate comprises an assembly of one or more sheets of homogenized tobacco material. The one or more sheets of homogenized tobacco material may be textured. As used herein, the term "textured sheet" refers to a sheet that is crimped, embossed, debossed, perforated, or otherwise modified. A textured sheet of homogenized tobacco material used in the present invention may include a plurality of spaced apart indentations, protrusions, perforations, or a combination thereof. The rod of the aerosol-forming substrate may comprise an assembly of crimped sheets of homogenized tobacco material surrounded by a wrapper.

[0181] In certain preferred embodiments, the aerosol-forming substrate comprises homogenized plant material, preferably homogenized tobacco material.

[0182] As used herein, the term "homogenized plant material" encompasses any plant material formed by agglomeration of plant particles. For example, a sheet or web of homogenized tobacco material for the aerosol-forming substrate of the present invention may be formed by agglomerating particles of tobacco material obtained by grinding, crushing, or comminuting plant material and, optionally, one or more of tobacco lamina and tobacco stems. Homogenized plant material may be produced by casting, extrusion, a papermaking process, or any other suitable process known in the art.

[0183] The homogenized plant material may be provided in any suitable form. For example, the homogenized plant material may be in the form of one or more sheets. The term "sheet" as used herein with respect to the present invention describes a thin layer of material having a width and length that is significantly greater than its thickness.

[0184] Alternatively, or additionally, the homogenized plant material may be in the form of a plurality of pellets or granules.

[0185] Alternatively, or additionally, the homogenized plant material may be in the form of a plurality of strands, pieces, or fragments. As used herein, the term "strand" describes an elongated element of material having a length substantially greater than its width and thickness. The term "strand" is intended to encompass pieces, fragments, and any other homogenized plant material having a similar morphology. Strands of homogenized plant material may be formed from a sheet of homogenized plant material, for example, by cutting or chopping, or by other methods, such as extrusion methods.

[0186] As used herein, the term "crimped sheet" is intended to be synonymous with the term "creased sheet" and refers to a sheet with a plurality of substantially parallel ridges or corrugations. Preferably, the crimped sheet of homogenized tobacco material has a plurality of ridges or corrugations that are substantially parallel to the cylindrical axis of the rod of the present invention. This advantageously facilitates assembly of the crimped sheet of homogenized tobacco material to form a rod. However, it will be understood that the crimped sheet of homogenized tobacco material used in the present invention may alternatively, or additionally, have a plurality of substantially parallel ridges or corrugations that are arranged at an acute or obtuse angle relative to the cylindrical axis of the rod. In certain embodiments, the sheet of homogenized tobacco material used in the rod of the article of the present invention may be substantially uniformly textured across substantially its entire surface. For example, the crimped sheet of homogenized tobacco material used to manufacture the rod for use in the aerosol-generating article of the present invention may include a plurality of substantially parallel ridges or corrugations that are substantially uniformly spaced across the width of the sheet.

[0187] The sheets or webs of homogenized tobacco material used in the present invention may have a tobacco content of at least about 40 weight percent on a dry weight basis, more preferably at least about 60 weight percent on a dry weight basis, even more preferably at least about 70 weight percent on a dry weight basis, and most preferably at least about 90 weight percent on a dry weight basis.

[0188] A sheet or web of homogenized tobacco material for use in an aerosol-forming substrate may include one or more intrinsic binders (i.e., tobacco intrinsic binders), one or more extrinsic binders (i.e., tobacco extrinsic binders), or combinations thereof, to assist in agglomerating the particulate tobacco. Alternatively, or in addition, a sheet of homogenized tobacco material for use in an aerosol-forming substrate may include other additives, including, but not limited to, tobacco and non-tobacco fibers, aerosol formers, humectants, plasticizers, flavorants, fillers, aqueous and non-aqueous solvents, and combinations thereof.

[0189] The homogenized plant material or tobacco material includes tobacco particles or tobacco material in combination with non-tobacco plant flavor particles, which may be selected from one or more of ginger particles, rosemary particles, eucalyptus particles, clove particles, and star anise particles.

[0190] Suitable extrinsic binders for inclusion in sheets or webs of homogenized tobacco material for use in aerosol-forming substrates are known in the art and include, but are not limited to, gums (e.g., guar gum, xanthan gum, gum arabic, locust bean gum, etc.), cellulosic binders (e.g., hydroxypropyl cellulose, carboxymethyl cellulose, hydroxyethyl cellulose, methyl cellulose, ethyl cellulose, etc.), polysaccharides (e.g., starch, organic acids (e.g., alginic acid), conjugate base salts of organic acids (e.g., sodium alginate), agar, pectin, etc.), and combinations thereof.

[0191] Suitable non-tobacco fibers for inclusion in sheets or webs of homogenized tobacco material for use in aerosol-forming substrates are known in the art and include, but are not limited to, cellulose fibers, softwood fibers, hardwood fibers, jute fibers, and combinations thereof. Prior to inclusion in sheets of homogenized tobacco material for use in aerosol-forming substrates, the non-tobacco fibers may be processed by any suitable process known in the art, including, but not limited to, mechanical pulping, refining, chemical pulping, bleaching, sulfate pulping, and combinations thereof.

[0192] In another embodiment of the present invention, the aerosol-forming substrate may comprise a gel composition comprising an alkaloid compound, or a cannabinoid compound, or both an alkaloid compound and a cannabinoid compound. The aerosol-forming substrate may comprise a gel composition comprising nicotine. The aerosol-forming substrate may comprise a gel composition without nicotine.

[0193] Preferably, the gel composition comprises an alkaloid compound, or a cannabinoid compound, or both an alkaloid compound and a cannabinoid compound, an aerosol former, and at least one gelling agent. Preferably, the at least one gelling agent forms a solid medium, the glycerol is dispersed in the solid medium, and the alkaloid or cannabinoid is dispersed in the glycerol. Preferably, the gel composition is in a stable gel phase.

[0194] Advantageously, the stable gel composition comprising nicotine provides a predictable composition shape upon storage or during transition from manufacture to consumer. The stable gel composition comprising nicotine substantially maintains its shape. The stable gel composition comprising nicotine does not substantially release a liquid phase upon storage or during transition from manufacture to consumer. The stable gel composition comprising nicotine may provide a simple consumable design. The consumable may not need to be designed to contain a liquid, and therefore a wider range of materials and container configurations may be contemplated.

[0195] The gel compositions described herein may be combined with an aerosol generating device to provide nicotine aerosol to the lungs at inhalation or airflow rates within those of traditional smoking. The aerosol generating device may continuously heat the gel composition. The consumer may take multiple inhalations or "puffs," with each "puff" delivering a quantity of nicotine aerosol. Upon heating, the gel composition may deliver a high nicotine / total particulate matter (TPM) aerosol to the consumer, preferably in a continuous manner.

[0196] The phrase "stable gel phase" or "stable gel" refers to a gel that substantially maintains its shape and mass when exposed to various environmental conditions. A stable gel cannot substantially release or absorb water (sweat) when exposed to standard temperatures and pressures while varying relative humidity from about 10 percent to about 60 percent. For example, a stable gel can substantially maintain its shape and mass when exposed to standard temperatures and pressures while varying relative humidity from about 10 percent to about 60 percent.

[0197] The gel composition may contain an alkaloid compound, or a cannabinoid compound, or both an alkaloid compound and a cannabinoid compound. The gel composition may contain one or more alkaloids. The gel composition may contain one or more cannabinoids. The gel composition may contain a combination of one or more alkaloids and one or more cannabinoids.

[0198] The term "alkaloid compound" refers to any one or more classes of naturally occurring organic compounds containing one or more basic nitrogen atoms. Generally, alkaloids contain at least one nitrogen atom in an amine-type structure. This or another nitrogen atom within the molecule of an alkaloid compound can be active as a base in an acid-base reaction. Most alkaloid compounds have one or more of their nitrogen atoms as part of a ring system, e.g., a heterocycle. In nature, alkaloid compounds are found primarily in plants and are particularly common in certain families of flowering plants. However, some alkaloid compounds are found in animal species and fungi. In this disclosure, the term "alkaloid compound" refers to both naturally occurring and synthetically produced alkaloid compounds.

[0199] The gel composition preferably comprises an alkaloid compound selected from the group consisting of nicotine, anatabine, and combinations thereof.

[0200] Preferably, the gel composition comprises nicotine.

[0201] The term "nicotine" refers to nicotine and nicotine derivatives (eg, free base nicotine, nicotine salts, and the like).

[0202] The term "cannabinoid compounds" refers to any one of a class of naturally occurring compounds found in parts of the cannabis plant, including Cannabis sativa, Cannabis indica, and Cannabis ruderalis. Cannabinoid compounds are particularly concentrated in the female flower heads. Cannabinoid compounds naturally occurring in the cannabis plant include cannabidiol (CBD) and tetrahydrocannabinol (THC). In this disclosure, the term "cannabinoid compounds" is used to describe both naturally occurring and synthetically produced cannabinoid compounds.

[0203] The gel may comprise a cannabinoid compound selected from the group consisting of cannabidiol (CBD), tetrahydrocannabinol (THC), tetrahydrocannabinolic acid (THCA), cannabidiolic acid (CBDA), cannabinol (CBN), cannabigerol (CBG), cannabichromene (CBC), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM), cannabielsoin (CBE), cannabicitran (CBT), and combinations thereof.

[0204] The gel composition may preferably comprise a cannabinoid compound selected from the group consisting of cannabidiol (CBD), THC (tetrahydrocannabinol) and combinations thereof.

[0205] The gel preferably contains cannabidiol (CBD).

[0206] The gel composition may include nicotine and cannabidiol (CBD).

[0207] The gel composition may include nicotine, cannabidiol (CBD), and THC (tetrahydrocannabinol).

[0208] The gel composition preferably includes an aerosol former. Ideally, the aerosol former is substantially resistant to thermal degradation at the operating temperature of the associated aerosol-generating device. Suitable aerosol formers include, but are not limited to, polyhydric alcohols (e.g., triethylene glycol, 1,3-butanediol, glycerin), esters of polyhydric alcohols (e.g., glycerol monoacetate, diacetate, or triacetate), and aliphatic esters of monocarboxylic, dicarboxylic, or polycarboxylic acids (e.g., dimethyl dodecanedioate, dimethyl tetradecanedioate). The polyhydric alcohol or mixture thereof may be one or more of triethylene glycol, 1,3-butanediol, and glycerin (glycerol or propane-1,2,3-triol) or polyethylene glycol. The aerosol former is preferably glycerol.

[0209] Preferably, as described above, in embodiments in which the rod of aerosol-forming substrate comprises a gel composition, the downstream section of the aerosol-generating article comprises an aerosol cooling element having a length of less than about 10 millimeters. The use of a relatively short aerosol cooling element in combination with a gel composition has been found to optimize delivery of the aerosol to the consumer.

[0210] Embodiments of the present invention in which the rod of aerosol-forming substrate comprises the gel composition described above preferably comprise an upstream element (or upstream section) upstream of the rod of aerosol-forming substrate. In this case, the upstream element or section advantageously prevents physical contact with the gel composition. The upstream element or section can also advantageously compensate for any potential decrease in RTD due to evaporation of the gel composition, for example, when the rod of aerosol-forming substrate is heated during use.

[0211] The sheet or web of homogenized tobacco material may include an aerosol former. As used herein, the term "aerosol former" describes any suitable known compound or mixture of compounds that facilitates the formation of an aerosol during use and that is substantially resistant to thermal decomposition at the operating temperatures of the aerosol-generating article.

[0212] Suitable aerosol formers are known in the art and include, but are not limited to, polyhydric alcohols (such as propylene glycol, triethylene glycol, 1,3-butanediol, glycerin, etc.), esters of polyhydric alcohols (such as glycerol monoacetate, diacetate, triacetate, etc.), and aliphatic esters of mono-, di-, or polycarboxylic acids (such as dimethyl dodecanedioate, dimethyl tetradecanedioate, etc.).

[0213] Preferred aerosol formers are polyhydric alcohols such as propylene glycol, triethylene glycol, 1,3-butanediol, and most preferably glycerin, or mixtures thereof.

[0214] The sheet or web of homogenized tobacco material may include a single aerosol former. Alternatively, the sheet or web of homogenized tobacco material may include a combination of two or more aerosol formers.

[0215] The homogenized sheet or web of tobacco material has an aerosol former content of greater than 10 percent on a dry weight basis. Preferably, the homogenized sheet or web of tobacco material has an aerosol former content of greater than 12 percent on a dry weight basis. More preferably, the homogenized sheet or web of tobacco material has an aerosol former content of greater than 14 percent on a dry weight basis. Even more preferably, the homogenized sheet or web of tobacco material has an aerosol former content of greater than 16 percent on a dry weight basis.

[0216] The sheet of homogenized tobacco material may have an aerosol former content of from about 10 percent to about 30 percent on a dry weight basis. Preferably, the sheet or web of homogenized tobacco material has an aerosol former content of less than 25 percent on a dry weight basis.

[0217] In one preferred embodiment, the sheet of homogenized tobacco material has an aerosol former content of approximately 20 percent on a dry weight basis.

[0218] The homogenized tobacco sheets or webs used in the aerosol-generating articles of the present invention may be made by methods known in the art (e.g., the method disclosed in International Patent Application No. WO-A-2012 / 164009(A2)). In one preferred embodiment, the sheets of homogenized tobacco material used in the aerosol-generating articles are formed by a casting process from a slurry comprising particulate tobacco, guar gum, cellulose fibers, and glycerin.

[0219] Alternative arrangements of homogenized tobacco material within a rod for use in an aerosol-generating article are known to those skilled in the art and may include multiple stacked sheets of homogenized tobacco material, multiple elongated tubular elements formed by winding strips of homogenized tobacco material around a longitudinal axis, and the like.

[0220] As a further alternative, the rod of aerosol-forming substrate may comprise a non-tobacco-derived nicotine-containing material, such as a sheet of absorbent non-tobacco material loaded with nicotine (e.g., in the form of a nicotine salt) and an aerosol former. Examples of such rods are described in International Application No. WO-A-2015 / 052652. Additionally or alternatively, the rod of aerosol-forming substrate may comprise a non-tobacco plant material, such as a flavorful non-tobacco plant material.

[0221] The aerosol-forming substrate is surrounded by a wrapper. The wrapper may be made of a porous or non-porous sheet material. The wrapper may be made of any suitable material or combination of materials. Preferably, the wrapper is a paper wrapper.

[0222] The mouthpiece segment includes a plug of filtration material capable of removing particulate components, gaseous components, or a combination thereof. Suitable filtration materials are known in the art and include, but are not limited to, fibrous filtration materials such as cellulose acetate tow, viscose fibers, polyhydroxyalkanoic acid (PHA) fibers, polylactic acid (PLA) fibers, and paper; adsorbents such as activated alumina, zeolites, molecular sieves, and silica gel; and combinations thereof. In addition, the plug of filtration material may further include one or more aerosol modifiers. Suitable aerosol modifiers are known in the art and include, but are not limited to, flavorings such as menthol. In some embodiments, the mouthpiece segment may further include a recess in the mouth end downstream of the plug of filtration material. As an example, the mouthpiece segment can include a hollow tube longitudinally aligned with the plug of filtration material and disposed immediately downstream of the plug of filtration material, the hollow tube forming a cavity in the mouth end that is open to the outside environment at the downstream end of the mouthpiece segment and the aerosol-generating article.

[0223] Preferably, the length of the mouthpiece segment is at least about 4 millimeters, more preferably at least about 6 millimeters, and even more preferably at least about 8 millimeters. Additionally or alternatively, the length of the mouthpiece segment is preferably less than 25 millimeters, more preferably less than 20 millimeters, and even more preferably less than 15 millimeters. In some preferred embodiments, the length of the mouthpiece segment is between about 4 millimeters and about 25 millimeters, and more preferably between about 6 millimeters and about 20 millimeters. The length of the mouthpiece segment may be about 7 millimeters. The length of the mouthpiece segment may be about 12 millimeters.

[0224] Preferably, the length of the hollow tubular segment is at least about 10 millimeters. More preferably, the length of the hollow tubular segment is at least about 15 millimeters. Additionally or alternatively, the length of the hollow tubular segment is preferably less than about 30 millimeters. More preferably, the length of the hollow tubular segment is less than about 25 millimeters. Even more preferably, the length of the hollow tubular segment is less than about 20 millimeters. In some preferred embodiments, the length of the hollow tubular segment is between about 10 millimeters and about 30 millimeters, more preferably between about 12 millimeters and about 25 millimeters, and even more preferably between about 15 millimeters and about 20 millimeters. By way of example, in one particularly preferred embodiment, the length of the hollow tubular segment is about 18 millimeters. In another particularly preferred embodiment, the length of the hollow tubular segment is about 13 millimeters.

[0225] Preferably, the length of the aerosol cooling element is at least about 10 millimeters. More preferably, the length of the aerosol cooling element is at least about 15 millimeters. Additionally or alternatively, the length of the aerosol cooling element is preferably less than about 30 millimeters. More preferably, the length of the aerosol cooling element is less than about 25 millimeters. Even more preferably, the length of the aerosol cooling element is less than about 20 millimeters. In some preferred embodiments, the length of the aerosol cooling element is between about 10 millimeters and about 30 millimeters, more preferably between about 12 millimeters and about 25 millimeters, and even more preferably between about 15 millimeters and about 20 millimeters. By way of example, in one particularly preferred embodiment, the length of the aerosol cooling element is about 18 millimeters. In another particularly preferred embodiment, the length of the aerosol cooling element is about 13 millimeters.

[0226] Preferably, the total length of an aerosol-generating article according to the present invention is at least about 40 millimeters. Additionally or alternatively, the total length of an aerosol-generating article according to the present invention is preferably less than about 70 millimeters, more preferably less than 60 millimeters, and even more preferably less than 50 millimeters. In preferred embodiments, the total length of an aerosol-generating article is between about 40 millimeters and about 70 millimeters. In an exemplary embodiment, the total length of an aerosol-generating article is about 45 millimeters.

[0227] The support elements (or support segments) can have a length of about 5 millimeters to about 15 millimeters. In a preferred embodiment, the support elements have a length of about 8 millimeters.

[0228] Preferably, the aerosol-generating article has an overall RTD of less than about 90 millimeters of H2O (about 900 Pa). More preferably, the aerosol-generating article has an overall RTD of less than about 80 millimeters of H2O (about 800 Pa). Even more preferably, the aerosol-generating article has an overall RTD of less than about 70 millimeters of H2O (about 700 Pa).

[0229] Additionally or alternatively, the aerosol-generating article preferably has an overall RTD of at least about 30 millimeters HO (about 300 Pa). More preferably, the aerosol-generating article has an overall RTD of at least about 40 millimeters HO (about 400 Pa). Even more preferably, the aerosol-generating article has an overall RTD of at least about 50 millimeters HO (about 500 Pa).

[0230] The RTD of an aerosol-generating article may be evaluated as the negative pressure that must be applied to the downstream end of the mouthpiece to maintain a steady volumetric flow rate of 17.5 ml / s of air through the mouthpiece under test conditions as defined in ISO 3402. The RTD values ​​listed above are intended to be measured on the aerosol-generating article on its own (i.e., before inserting the article into an aerosol-generating device), without sealing off the ventilation zone perforations.

[0231] As used herein, the term "homogenized tobacco material" encompasses any tobacco material formed by agglomeration of particles of tobacco material. A sheet or web of homogenized tobacco material is formed by agglomerating particulate tobacco obtained by grinding or otherwise pulverizing one or both of tobacco lamina and tobacco stem. In addition, the homogenized tobacco material may contain one or more small amounts of tobacco dust, tobacco fines, and other particulate tobacco by-products formed during tobacco processing, handling, and shipping. A sheet of homogenized tobacco material may be produced by casting, extrusion, a papermaking process, or any other suitable process known in the art.

[0232] The support element may be formed from any suitable material or combination of materials. For example, the support element may be formed from one or more materials selected from the group consisting of cellulose acetate, cardboard, crimped paper (such as crimped heat-resistant paper or crimped parchment paper), and polymeric materials (such as low-density polyethylene (LDPE)). In a preferred embodiment, the support element is formed from cellulose acetate.

[0233] The aerosol generating device may include an extractor for extracting an aerosol-generating article received within the aerosol generating device, the extractor being configured to be movable within the device cavity.

[0234] The extractor may be configured to expose the airflow channel when the extractor is in an operating position, the operating position being defined by the heater contacting the aerosol-forming substrate of the aerosol-generating article.

[0235] The extractor comprises a container body configured to receive the aerosol-generating article. The container body of the extractor (extractor body) may comprise an end wall and a peripheral wall. The container body of the extractor comprises an open end opposite the end wall, through which the aerosol-generating article can be received. The aerosol-generating article is configured to abut against the end wall when received within the extractor body. The peripheral wall of the container body may surround the aerosol-generating article when received within the extractor. In such embodiments in which an extractor is present, the peripheral wall of the extractor body may define an airflow channel. Alternatively, the peripheral wall of the device housing may define the airflow channel.

[0236] The extractor may be sized so that, in the operating position, the container body extends between the first end of the airflow channel and the distal end of the device cavity, allowing the aerosol-generating article to be directly exposed to the airflow channel without the extractor body obscuring fluid communication between the airflow channel and the aerosol-generating article.

[0237] The extractor may be sized so that, in the operating position, the container body extends between the mouth end of the device cavity and the distal end of the device cavity. In such embodiments, the extractor body may have a cutout or cutouts to expose the airflow channel to the aerosol-generating article when inserted. The extractor body and the device cavity may together be configured to ensure alignment of the cutout or cutouts with the airflow channel or channels during use. For example, the extractor body may include a protrusion arranged to cooperate with a slot or groove located in the housing of the aerosol-generating device.

[0238] The aerosol-generating device may include an elongated heater arranged to be inserted into the aerosol-generating article when the aerosol-generating article is received in the device cavity. The elongated heater may be arranged with the device cavity. The elongated heater may extend into the device cavity. Alternative heating arrangements are discussed further below. However, in such embodiments in which the heater extends into the device cavity, the extractor body includes an opening in the end wall to allow the heater to extend into the aerosol-generating article. Such an opening may allow air to enter the interior of the extractor cavity so that air can flow through the rod of the aerosol-forming substrate of the aerosol-generating article during use. Alternatively, a further opening may be provided to allow air to enter the interior of the extractor cavity.

[0239] In some embodiments, the length of the extractor body may be less than the length of the device cavity. In such embodiments, when the extractor is in the operative position (when the extractor abuts the distal end of the device cavity), the airflow channel may be defined by a portion of the peripheral wall of the device housing that does not surround the extractor. This portion of the peripheral wall may define the airflow channel when the extractor is in the operative position. Effectively, this portion of the peripheral wall of the device housing may extend longitudinally beyond the extractor to define the airflow channel. The space or gap between the aerosol-generating article and the peripheral wall of the device housing defines the airflow channel.

[0240] In embodiments in which an extractor is provided, an airflow channel may be defined between the peripheral wall of the aerosol generating device housing and the exterior surface of the extractor. Alternatively, the airflow channel may be defined within the extractor body. The airflow channel may be defined in the peripheral wall of the extractor body. The airflow channel may be defined within the thickness of the peripheral wall of the extractor body. The airflow channel may extend along the length of the extractor body. The airflow channel may extend from a longitudinal position away from the end wall of the extractor body to a longitudinal position near or at the open end of the extractor body.

[0241] In embodiments where an extractor is not provided, the airflow channel may be defined within the thickness of the peripheral wall of the aerosol generation device housing.

[0242] The heater may comprise an elongated heating element configured to pass through the rod of the aerosol-forming substrate when the aerosol-generating article is received within the aerosol-generating device.

[0243] The heater may be any suitable type of heater. The heater may initially heat the aerosol-generating article. Alternatively, the heater may heat the aerosol-generating article externally. Such an external heater may surround the aerosol-generating article when inserted or received within the aerosol-generating device.

[0244] In some embodiments, the heater is arranged to heat the outer surface of the aerosol-forming substrate. In some embodiments, the heater is arranged to be inserted into the aerosol-forming substrate when the aerosol-forming substrate is received in the cavity. The heater may be located within the cavity. The heater may extend into the cavity. The heater may be an elongated heater. The elongated heater may be blade-shaped. The elongated heater may be pin-shaped. The elongated heater may be cone-shaped. In some embodiments, the aerosol-generating device comprises an elongated heater arranged to be inserted into the aerosol-generating article when the aerosol-generating article is received in the cavity.

[0245] The heater may include at least one heating element. The at least one heating element may be of any suitable type. In some embodiments, the device includes only one heating element. In some embodiments, the device includes multiple heating elements. The heater may include at least one resistive heating element. Preferably, the heater includes multiple resistive heating elements. The resistive heating elements are preferably electrically connected in a parallel configuration. Advantageously, providing multiple resistive heating elements electrically connected in a parallel configuration may facilitate delivery of desired power to the heater while reducing or minimizing the voltage required to provide the desired power. Advantageously, reducing or minimizing the voltage required to operate the heater may facilitate reducing or minimizing the physical size of the power supply.

[0246] Suitable materials for forming the at least one resistive heating element include, but are not limited to, semiconductors such as doped ceramics, "conductive" ceramics (e.g., molybdenum disilicide), carbon, graphite, metals, metal alloys, and composites made of ceramic and metallic materials. Such composites may include doped or undoped ceramics. An example of a suitable doped ceramic is doped silicon carbide. Examples of suitable metals include titanium, zirconium, tantalum, and platinum group metals. Examples of suitable metal alloys include stainless steel, nickel-, cobalt-, chromium-, aluminum-, titanium-, zirconium-, hafnium-, niobium-, molybdenum-, tantalum-, tungsten-, tin-, gallium-, manganese-, and iron-containing alloys, as well as nickel-, iron-, cobalt-, and stainless steel-based superalloys, Timetal®, and iron-manganese-aluminum-based alloys.

[0247] In some embodiments, the at least one resistive heating element comprises one or more stamped sections of an electrically resistive material (such as stainless steel). Alternatively, the at least one resistive heating element may comprise a heating wire or filament (e.g., Ni-Cr (nickel-chromium), platinum, tungsten, or alloy wire).

[0248] In some embodiments, the at least one heating element comprises an electrically insulating substrate and the at least one resistive heating element is provided on the electrically insulating substrate.

[0249] The electrically insulating substrate may comprise any suitable material. For example, the electrically insulating substrate may comprise one or more of paper, glass, ceramic, anodized metal, coated metal, and polyimide. The ceramic may comprise mica, alumina (Al2O3), or zirconia (ZrO2). The electrically insulating substrate preferably has a thermal conductivity of about 40 watts per meter Kelvin or less, preferably about 20 watts per meter Kelvin or less, and ideally about 2 watts per meter Kelvin or less.

[0250] The heater may comprise a heating element comprising a rigid, electrically insulating substrate having one or more conductive tracks or wires arranged on its surface. Depending on the size and shape of the electrically insulating substrate, the heater may be able to be inserted directly into the aerosol-forming substrate. If the electrically insulating substrate is not sufficiently rigid, the heating element may comprise additional reinforcing means. An electric current may be passed through one or more conductive tracks to heat the heating element and the aerosol-forming substrate.

[0251] In some embodiments, the heater comprises an induction heating arrangement. The induction heating arrangement may comprise an inductor coil and a power source configured to provide a high-frequency oscillating current to the inductor coil. As used herein, high-frequency oscillating current refers to an oscillating current having a frequency between 500 kHz and 30 MHz. The heater may advantageously include a DC / AC inverter for converting DC current provided by a DC power source into alternating current. The inductor coil may be configured to generate a high-frequency oscillating electromagnetic field upon receiving the high-frequency oscillating current from the power source. The inductor coil may be configured to generate a high-frequency oscillating electromagnetic field within the device cavity. In some embodiments, the inductor coil may substantially surround the device cavity. The inductor coil may extend at least partially along the length of the device cavity.

[0252] The heater may include an induction heating element. The induction heating element may be a susceptor element. As used herein, the term "susceptor element" refers to an element comprising a material capable of converting electromagnetic energy into heat. When the susceptor element is positioned within an alternating electromagnetic field, the susceptor is heated. Heating of the susceptor element may be the result of at least one of hysteresis losses and eddy currents induced within the susceptor, depending on the electrical and magnetic properties of the susceptor material.

[0253] The susceptor element may be positioned such that, when an aerosol-generating article is received within the cavity of the aerosol generating device, the oscillating electromagnetic field generated by the inductor coil induces a current in the susceptor element, heating the susceptor element. In these embodiments, the aerosol generating device is preferably capable of generating a fluctuating electromagnetic field having a magnetic field strength (H-field strength) of 1 to 5 kiloamperes per meter (kA / m), preferably 2 to 3 kA / m, e.g., about 2.5 kA / m. Electrically operated aerosol generating devices are preferably capable of generating a fluctuating electromagnetic field having a frequency of 1 to 30 MHz, e.g., 1 to 10 MHz, e.g., 5 to 7 MHz.

[0254] In some embodiments, the susceptor element is located within the aerosol-generating article. In these embodiments, the susceptor element is preferably located in contact with the aerosol-forming substrate. The susceptor element may be located within the aerosol-forming substrate.

[0255] In some embodiments, the susceptor element is located within the aerosol-generating device. In these embodiments, the susceptor element may be located within a cavity. The aerosol-generating device may include only one susceptor element. The aerosol-generating device may include multiple susceptor elements.

[0256] In some embodiments, the susceptor element is arranged to heat the outer surface of the aerosol-forming substrate, hi some embodiments, the susceptor element is arranged to be inserted into the aerosol-forming substrate when the aerosol-forming substrate is received within the cavity.

[0257] The susceptor element may comprise any suitable material. The susceptor element may be formed from any material that can be inductively heated to a temperature sufficient to release volatile compounds from the aerosol-forming substrate. Suitable materials for the elongated susceptor element include graphite, molybdenum, silicon carbide, stainless steel, niobium, aluminum, nickel, nickel-containing compounds, titanium, and composites of metallic materials. Some susceptor elements comprise metal or carbon. Advantageously, the susceptor element may comprise or consist of a ferromagnetic material, such as ferromagnetic alloys (e.g., ferritic iron, ferromagnetic steel, or stainless steel), ferromagnetic particles, and ferrite. Suitable susceptor elements may be or include aluminum. The susceptor element preferably comprises more than about 5 percent, preferably more than about 20 percent, more preferably more than about 50 percent, or more than about 90 percent, of ferromagnetic or paramagnetic material. Some elongated susceptor elements may be heated to temperatures greater than about 250 degrees Celsius.

[0258] The susceptor element may comprise a non-metallic core having a metallic layer disposed thereon. For example, the susceptor element may include a ceramic core or metallic tracks formed on the outer surface of the substrate.

[0259] In some embodiments, the aerosol generating device may comprise at least one resistive heating element and at least one inductive heating element, hi some embodiments, the aerosol generating device may comprise a combination of resistive and inductive heating elements.

[0260] The aerosol-generating device may include a power source. The power source may be a DC power source. In some embodiments, the power source is a battery. The power source may be a nickel-metal hydride battery, a nickel-cadmium battery, or a lithium-based battery (e.g., lithium cobalt, lithium iron phosphate, or lithium polymer battery). However, in some embodiments, the power source may be another form of charge storage device, such as a capacitor. The power source may be rechargeable and may have a capacity that allows for the storage of sufficient energy for one or more user operations, e.g., one or more aerosol-generating experiences. For example, the power source may have a capacity sufficient to allow continuous heating of the aerosol-forming substrate for approximately six minutes, corresponding to the typical time it takes to smoke a conventional cigarette, or a multiple of six minutes. In another example, the power source may have a capacity sufficient to allow for a predetermined number of puffs or for discontinuous activation of the heater. [Brief explanation of the drawings]

[0261] Specific embodiments will now be described with reference to the figures.

[0262] [Figure 1] FIG. 1 is a schematic cross-sectional view of one embodiment of an aerosol generation system according to the present disclosure. [Figure 2] FIG. 2 is a schematic cross-sectional view of one embodiment of an aerosol-generating article according to the present invention. [Figure 3]FIG. 3 is a schematic cross-sectional view of one embodiment of an aerosol generation system according to the present disclosure. [Figure 4] FIG. 4 is a schematic cross-sectional view of one embodiment of an aerosol-generating article according to the present invention. [Figure 5] FIG. 5 is a schematic cross-sectional view of one embodiment of an aerosol generation system according to the present disclosure. [Figure 6] FIG. 6 is a schematic cross-sectional view of a comparative example of an aerosol generation system. DETAILED DESCRIPTION OF THE INVENTION

[0263] FIG. 1 illustrates an aerosol generation system 100 comprising an aerosol generating device 10 and an aerosol-generating article 1. The aerosol generating device 10 comprises a housing 4 extending between an oral end 2 and a distal end (not shown). The housing 4 comprises a peripheral wall 6. The peripheral wall 6 defines a device cavity for receiving the aerosol-generating article 1. The device cavity is defined by a closed distal end and an open oral end. The oral end of the device cavity is located at the oral end of the aerosol generating device 10. The aerosol-generating article 1 is configured to be received through the oral end of the device cavity and abuts against the closed end of the device cavity. The length of the device cavity is approximately 25 mm.

[0264] An airflow channel 5 is defined within the peripheral wall 6. The airflow channel 5 extends between an inlet 7 located at the mouth end of the aerosol generation device 10 and an outlet 9 located at a distal position along the peripheral wall 6.

[0265] The aerosol-generating device 10 further comprises a heater (not shown) and a power supply (not shown) for supplying power to the heater. A controller (not shown) is also provided for controlling such a power supply to the heater. The heater is configured to heat the aerosol-generating article 1 during use when the aerosol-generating article 1 is received within the device 10.

[0266] The aerosol-generating article 1 comprises a first air entry zone 15 and a second air entry zone 115 located along the wrapper 22. The first air entry zone 15 comprises a porous portion of the wrapper 22. The porous portion forming the first air entry zone 15 is approximately 3 mm wide. The first and second air entry zones 15, 115 are separated by a distance of approximately 1.5 mm.

[0267] 1 and 2, the second air entry zone 115 comprises a row of perforations that penetrate the wrapper 22. The second air entry zone 115 is located approximately 1.5 mm downstream from the first air entry zone 15. Both the first air entry zone 15 and the second air entry zone 115 are located along the rod of the aerosol-forming substrate 12. The first air entry zone 15 is located approximately 2 mm downstream from the upstream end of the rod of the aerosol-forming substrate 12.

[0268] When the aerosol-generating article 1 is received within the device cavity, the outlet 9 is configured to align with or cover the first air entry zone 15. Once received within the device cavity, the upstream end of the aerosol-generating article 1 is disposed to abut the closed end of the device cavity such that air drawn through the aerosol-generating device 10 does not flow through the upstream end of the aerosol-generating article 1. Air drawn through the aerosol-generating device 10 can enter the aerosol-generating article 1 only through the first and second air entry zones 15, 115, as shown in FIG.

[0269] An airflow channel 5 is defined along the inner surface of the peripheral wall 6. In such an embodiment, a portion of the airflow channel 5 is configured to cover the first and second air entry zones 15, 115 of the aerosol-generating article 1. The airflow channel 5 has a length of approximately 23 millimeters. In such an embodiment, shown in FIG. 1, the entire length of the airflow channel 5 is configured to cover the aerosol-generating article 1 when received within the device 10.

[0270] FIG. 2 shows an aerosol-generating article 1 configured for use in the aerosol-generating system 100 shown in FIG.

[0271] The aerosol-generating article 1 comprises an aerosol-forming substrate rod 12, a hollow support segment 14, an aerosol cooling element (or segment) 16, and a mouthpiece segment 18. The components downstream of the aerosol-forming substrate rod 12 (in this case, the hollow support segment 14, the aerosol cooling element 16, and the mouthpiece segment 18) form the downstream section of the aerosol-generating article 1. These four elements are longitudinally aligned end-to-end and surrounded by a wrapper 22 to form the aerosol-generating article 1. The aerosol-generating article 1 shown in Figure 1 is particularly suitable for use with an electrically operated aerosol generating device 1 that includes a heater for heating the aerosol-forming substrate rod 12.

[0272] The aerosol-forming substrate rod 12 has a length of about 12 millimeters and a diameter of about 7 millimeters. The rod 12 is cylindrical in shape and has a substantially circular cross-section. The rod 12 comprises a collection of sheets of homogenized tobacco material. The hollow cellulose acetate tube (hollow support segment) 14 has a length of about 8 millimeters and its peripheral wall has a thickness of 1 millimeter.

[0273] The mouthpiece segment 18 comprises a plug of 8 denier cellulose acetate tow per filament and has a length of approximately 7 millimeters. The mouthpiece segment 18 has a diameter of approximately 7 millimeters. The aerosol cooling element 16 has a length of approximately 18 mm and a diameter of approximately 7 mm.

[0274] The aerosol-generating article 1 comprises a first air entry zone 15 along the rod of aerosol-forming substrate at least about 2 millimeters from the upstream end of the rod of aerosol-forming substrate 12. The first air entry zone 15 is located less than 10 millimeters from the downstream end of the rod of aerosol-forming substrate 12 or the upstream end of the hollow support segment 14. The first and second air entry zones 15, 115 surround the aerosol-generating article 1. That is, the first and second air entry zones 15, 115 surround the entire periphery of the aerosol-generating article 1.

[0275] Figure 3 shows an aerosol generation system 200 similar to the aerosol generation system 100 shown in Figure 1. The aerosol generation system 200 shown in Figure 4 comprises an aerosol-generating device 10 and an aerosol-generating article 102. The aerosol generation system 200 differs from the aerosol generation system 100 in that a first air entry zone 215 is located along the rod of the aerosol-forming substrate 12 and a second air entry zone 315 is located along the hollow support segment 14 of the aerosol-generating article 102, as shown in Figure 4.

[0276] An aerosol-generating article 102 configured for use in an aerosol-generating system 200 is illustrated in FIG.

[0277] The first air entry zone 215 is located approximately 2 mm downstream of the upstream end of the aerosol-forming substrate rod 12. The second air entry zone 215 is located approximately 2 mm downstream of the upstream end of the hollow support segment 14 and approximately 2 mm downstream of the downstream end of the aerosol-forming substrate rod 12, considering that the aerosol-forming substrate rod 12 and the hollow support segment 14 are in direct contact. Thus, the two air entry zones 215, 315 are located along and around two different components of the aerosol-generating article 102.

[0278] 3, the first and second air entry zones 215, 315 each include a row of perforations that extend around the article 102 and through the wrapper 22. The second air entry zone 315 extends through the peripheral wall of the hollow support segment 14.

[0279] 5 shows aerosol generation system 200, which is similar to aerosol generation system 300. Aerosol generation system 300 comprises an aerosol-generating device 20 and an aerosol-generating article 102, both of which are configured to be used in conjunction with each other. Aerosol generation device 20 is similar to aerosol generation device 10, except that device 20 comprises an airflow channel 205 that includes an inlet 7 and two outlets 9, 19. The first outlet 9 of airflow channel 205 is configured to provide fluid communication between the exterior of aerosol-generating device 20 and a first air entry zone 215 of the aerosol-generating article 102. The second outlet 19 of airflow channel 205 is configured to provide fluid communication between the exterior of aerosol-generating device 20 and a second air entry zone 315 of the aerosol-generating article 102. The first outlet 9 is configured to cover (or overlap) the first air entry zone 215 when the article 102 is received within the apparatus 20, and the second outlet 19 is configured to cover (or overlap) the second air entry zone 315 when the article 102 is received within the apparatus 20. The spacing or distance between the first outlet 9 and the second outlet 19 may be equal to the distance between the first air entry zone 215 and the second air entry zone 315.

[0280] 1, 3 and 5, fluid communication between the exterior of the aerosol-generating device 10, 20 and the interior of the aerosol-generating article 1, 102 is established via two different air entry zones 15, 115 and 215, 315. However, the first air entry zone 15, 215 is configured to allow more air to pass through it than the second air entry zone 115, 315. In other words, the first air entry zone 15, 215 is configured to provide a higher level of air entry than the second air entry zone 115, 315.

[0281] The first air entry zone 15, 215 is configured to be the primary air entrainment zone for the aerosol-generating article 1, 102 when the article 1, 102 is received within the device 10, 20, upon abutment of the upstream end of the article 1, 102 with the distal end of the device cavity. The second air entry zone 115, 315 is configured to provide ventilation for the article 1, 102, i.e., to vent the aerosol flowing from the rod 12 of the aerosol-forming substrate through the hollow support segment 14 towards the mouth end of the article 1, 102.

[0282] When received within the aerosol generating device 10, 20, the upstream end of the aerosol-generating article 1, 102 abuts the distal end of the device cavity to prevent air from flowing through the upstream end of the aerosol-generating article 1, 102. Thus, during use, the majority of the air flowing through the airflow channel 5, 205 is configured to flow through the first air entry zone 15, 215 due to the overlap between the airflow channel outlet 9 and the first air entry zone 15, 215.

[0283] 6 shows a comparative example of a non-compliant aerosol-generating article 103 that does not have a first air entry zone located around the rod of aerosol-forming substrate for use with the aerosol-generating device 10. Because the article 103 does not have an air entry zone and the upstream end of the article 103 abuts the distal end of the device cavity, air is not drawn through the article 103.

[0284] 1 and 3, the aerosol generation device 10 comprises an annular airflow channel 5. The aerosol generation device 20 shown in FIG.

[0285] Unless otherwise specified, the aerosol-generating articles 1, 102 described have the same structural components, such as the aerosol-forming substrate rod 12, hollow support segment 14, aerosol cooling element 16, and mouthpiece segment 18 disposed within a wrapper 22, but differ primarily in the configuration of the air entry zones provided on the articles.

Claims

1. 1. An aerosol-generating article for generating an aerosol upon heating, said aerosol-generating article comprising: a rod of aerosol-forming substrate, and a filter positioned downstream of the rod of the aerosol-forming substrate, the aerosol-forming substrate rod and the filter are assembled within a wrapper, the aerosol-generating article includes first and second air entry zones located on the wrapper, the first and second air entry zones being configured to allow air to enter the interior of the aerosol-generating article, respectively; The aerosol-generating article further comprises a first air entry zone comprising a substantially porous portion of the wrapper, the substantially porous portion having a porosity of at least 3000 Coresta units, and configured such that the level of air entry into the interior of the aerosol-generating article through the first air entry zone is greater than the level of air entry into the interior of the aerosol-generating article through the second air entry zone.

2. 2. The aerosol-generating article of claim 1, wherein the second air entry zone is located downstream of the first air entry zone.

3. 3. The aerosol-generating article according to claim 1, wherein the first air entry zone is located along the rod of the aerosol-forming substrate and the second air entry zone is located downstream of the rod of the aerosol-forming substrate.

4. The filter of the aerosol-generating article is a mouthpiece segment including a plug of filtration material located downstream of the rod of the aerosol-forming substrate; and 4. The aerosol-generating article according to claim 1, further comprising a hollow tubular segment located between the mouthpiece segment and the rod of the aerosol-forming substrate.

5. 5. The aerosol-generating article of claim 4, wherein the filter of the aerosol-generating article includes an aerosol-cooling element located between the mouthpiece segment and the hollow tubular segment.

6. 6. The aerosol-generating article of claim 4 or 5, wherein the second air entry zone is located along the hollow tubular segment.

7. 7. The aerosol-generating article according to claim 1, wherein the first air entry zone is located at least 2 mm downstream of the upstream end of the rod of the aerosol-forming substrate.

8. 8. The aerosol-generating article according to claim 1, wherein the second air entry zone is located at least 2 mm downstream of the downstream end of the rod of the aerosol-forming substrate.

9. 9. An aerosol-generating article according to any preceding claim, wherein the second air entry zone is located at least 2 mm downstream of the first air entry zone.

10. 10. An aerosol-generating article according to any one of claims 1 to 9, wherein the volume of the first air configured to enter the interior of the aerosol-generating article through the first air entry zone is at least 10% greater than the volume of air configured to enter the interior of the aerosol-generating article through the second air entry zone.

11. 11. An aerosol-generating article according to any preceding claim, wherein the second air entry zone comprises a substantially porous portion of the wrapper.

12. 11. The aerosol-generating article of any one of claims 1 to 10, wherein the first air entry zone or the second air entry zone comprises a plurality of openings through the wrapper.

13. 13. An aerosol-generating article according to any preceding claim, wherein the first air entry zone has a porosity of at least 5000 Coresta units.

14. An aerosol-generating article according to any preceding claim, wherein the wrapper of the aerosol-generating article comprises an air-impermeable material.

15. 15. An aerosol-generating article according to any preceding claim, wherein the width of the first air entry zone is at least 3 mm.

16. An aerosol-generating article as described in any one of claims 1 to 15, wherein the width of the first air entry zone is at least 5 mm.

17. 17. An aerosol-generating article according to any preceding claim, wherein the width of the first air entry zone is greater than the width of the second air entry zone.

18. An aerosol generating system comprising an aerosol-generating article according to any one of claims 1 to 17 and an aerosol generating device having a distal end and an oral end, a housing defining a device cavity for removably receiving the aerosol-generating article at the oral end of the device; a heater for heating the aerosol-forming substrate when the aerosol-generating article is received within the device cavity; and an airflow channel extending between a channel inlet and a channel outlet, the airflow channel configured to establish fluid communication between an interior of the device cavity and an exterior of the aerosol generation device; The aerosol generation system is configured such that when the aerosol-generating article is received within the device cavity, fluid communication between the interior of the aerosol-generating article and the exterior of the aerosol-generating device is established by fluid communication established between the first air entry zone of the aerosol-generating article received within the device cavity and the airflow channel of the aerosol-generating device.

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