Aerosol generating article with improved configuration

Abstract

An aerosol-generating article (10) for generating an inhalable aerosol upon heating is provided, the aerosol-generating article (10) including a rod of aerosol-generating substrate (12), a mouthpiece element (42) having a length of at least 10 millimeters, and an intermediate hollow section (50) between the rod of aerosol-generating substrate (12) and the mouthpiece element (42). The intermediate hollow section (50) includes an aerosol cooling element (24) axially aligned with and abutting the upstream end of the mouthpiece element (42), the aerosol cooling element (24) having a length of less than 10 millimeters and including a hollow tubular segment (34) defining a longitudinal cavity (36) providing an unrestricted flow channel, the hollow tubular segment having a wall thickness of between 1.5 millimeters and 2.5 millimeters.

Description

Technical Field

[0001] The present invention relates to an aerosol article comprising an aerosol generating substrate and adapted to generate an inhalable aerosol upon heating.

Background Art

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

[0003] Numerous prior art documents disclose aerosol generating devices for consuming aerosol articles. Such devices include, for example, an electrically heated aerosol generating device in which an aerosol is generated by heat transfer from one or more electric heater elements of the aerosol generating device to the aerosol generating substrate of the heated aerosol article. For example, an electrically heated aerosol generating device has been proposed that includes an internal heater blade adapted to be inserted into the aerosol generating substrate. Alternatively, an inductively heat-generating aerosol article comprising an aerosol generating substrate and a susceptor element disposed within the aerosol generating substrate has been proposed by WO2015 / 176898.

[0004] Aerosol-generating articles in which the tobacco-containing substrate is heated rather than burned present several challenges not encountered by conventional smoking articles. Firstly, the tobacco-containing substrate is typically heated to significantly lower temperatures compared to the temperature reached by the pre-burning portion of a conventional cigarette. This can affect nicotine release from the tobacco-containing substrate and nicotine delivery to the consumer. At the same time, if the heating temperature is increased in an attempt to promote nicotine delivery, the resulting aerosol typically needs to be cooled more widely and rapidly before reaching the consumer. However, technical solutions commonly used in conventional smoking articles to cool the mainstream smoke, such as providing a highly filtration-efficient segment at the mouth-end of the cigarette, may have undesirable effects in aerosol-generating articles in which the tobacco-containing substrate is heated rather than burned, as this can reduce nicotine delivery. Secondly, there is a general need for aerosol-generating articles that are generally easier to use and have improved practicality.

[0005] Therefore, it would be desirable to provide a new and improved aerosol-generating article adapted to achieve at least one of the desirable results described above. Furthermore, it would be desirable to provide one such aerosol-generating article that can be manufactured efficiently and quickly, preferably has a satisfactory RTD, and exhibits little RTD variation between articles. [Overview of the project]

[0006] This disclosure relates to an aerosol generating article comprising a rod of an aerosol generating substrate. The aerosol generating article may further comprise a mouthpiece element having a length of at least 10 millimeters. The aerosol generating article may comprise an intermediate hollow section between the rod of the aerosol generating substrate and the mouthpiece element. The intermediate hollow section may comprise an aerosol cooling element that is axially aligned with the mouthpiece element and abuts against the upstream end of the mouthpiece element. The aerosol cooling element may have a length of less than 10 millimeters. The aerosol cooling element may comprise a hollow tubular segment defining a longitudinal cavity that provides an unlimited flow channel. The hollow tubular segment may have a wall thickness of less than 2.5 millimeters.

[0007] According to the present invention, an aerosol generating article is provided for generating an inhalable aerosol upon heating, the aerosol generating article comprising a rod of an aerosol generating substrate, a mouthpiece element having a length of at least 10 millimeters, and an intermediate hollow section between the rod of the aerosol generating substrate and the mouthpiece element. The intermediate hollow section comprises an aerosol cooling element axially aligned with the mouthpiece element and in contact with the upstream end of the mouthpiece element, the aerosol cooling element having a length of less than 10 millimeters and comprising a hollow tubular segment defining a longitudinal cavity that provides an unlimited flow channel. According to the present invention, the hollow tubular segment has a wall thickness of less than 2.5 millimeters.

[0008] The term "aerosol-generating article" is used herein to mean an article in which an aerosol-generating substrate is heated to produce an inhalable aerosol that is delivered to the consumer. The term "aerosol-generating substrate" as used herein means a substrate having the ability to generate an aerosol by releasing volatile compounds upon heating.

[0009] Conventional cigarettes are ignited when the user holds a flame to one end of the cigarette and draws air through the other end. The localized heat from the flame and the oxygen in the air drawn through the cigarette ignites the end of the cigarette, and the resulting combustion produces inhalable smoke. In contrast, in heated aerosol generating articles, the aerosol is generated by heating a flavor-generating substrate (such as tobacco). Well-known heated aerosol generating articles include, for example, electrically heated aerosol generating articles and aerosol generating articles in which an aerosol is generated by heat transfer from a combustible fuel element or heat source to a physically separated aerosol-forming material. For example, the aerosol generating article according to the present invention has a particular application in an aerosol generating system comprising an electrically heated aerosol generating device having an internal heater blade adapted to be inserted into a rod of an aerosol generating substrate. This type of aerosol generating article is described in the prior art, e.g., EP0822670.

[0010] As used herein, the term "aerosol generator" refers to a device comprising a heater element that interacts with an aerosol-generating substrate of an aerosol-generating article to generate an aerosol.

[0011] As used herein in connection with the present invention, the term "rod" is used to refer to a generally cylindrical element having a substantially circular, oval, or elliptical cross-section.

[0012] As used herein, the term “longitudinal direction” refers to the direction corresponding to the main longitudinal axis of the aerosol generating article, extending between the upstream and downstream ends of the aerosol generating article. As used herein, the terms “upstream” and “downstream” describe the relative position of an element (or part of an element) of the aerosol generating article with respect to the direction in which aerosols are transported through the aerosol generating article during use.

[0013] During use, air is drawn longitudinally through the aerosol-generating article. The term "transverse direction" refers to a direction perpendicular to the longitudinal axis. Any reference to the "cross section" of the aerosol-generating article or its components refers to the transverse section unless otherwise specified.

[0014] The term "length" refers to the dimensions of the components of an aerosol-generating article in the longitudinal direction. For example, it may be used to refer to the dimensions of a rod or an elongated tubular element in the longitudinal direction.

[0015] As used herein, the term “hollow tubular segment” is generally used to mean an elongated element that defines a lumen or airflow passage along its longitudinal axis. In particular, the term “tubular” is used below with respect to a tubular element having a substantially cylindrical cross-section and defining at least one airflow conduit that establishes an uninterrupted fluid communication between the upstream and downstream ends of the tubular element. However, it will be understood that alternative shapes of tubular segments (e.g., alternative cross-sectional shapes) may be possible. A hollow tubular segment is an individual element of an aerosol-generating article having defined length and thickness.

[0016] As used herein, the term “slender” means that an element has a length dimension that is greater than its width dimension or diameter dimension, for example, more than twice its width dimension or diameter dimension.

[0017] In the context of the present invention, the hollow tubular segment provides an unlimited flow channel. This means that the hollow tubular segment provides a negligible level of drawdown resistance (RTD). Therefore, the flow channel should not contain any components that would obstruct the longitudinal airflow. Preferably, the flow channel is substantially empty.

[0018] The aerosol generating article according to the present invention provides an improved configuration of the downstream elements of the rod of an aerosol generating substrate, comprising a combination of a relatively long mouthpiece element having a length of at least 10 millimeters and an aerosol cooling element having a length of less than 10 millimeters, and formed from a hollow tubular segment having a relatively low wall thickness of less than 2.5 millimeters. This combination of elements has been found to achieve optimal aerosol delivery to the consumer during use. The aerosol cooling element has a relatively large internal volume as a result of the low wall thickness of the hollow tubular segment, which achieves optimal cooling and nucleation of the aerosol.

[0019] Advantageously, the wall thickness of the hollow tubular segment can be selected to a level of less than 2.5 millimeters, as described, which provides sufficient structural rigidity to prevent the collapse of the aerosol cooling element during use, while maintaining the advantages of improved cooling and nucleation. Constructing the aerosol cooling element as a relatively thin-walled hollow tubular segment means that the aerosol cooling element has a minimum level of drawdown resistance (RTD) and therefore does not affect the overall RTD of the aerosol generating article. Thus, the overall RTD of the aerosol generating article can be effectively adjusted by modifying the properties of the mouthpiece element, such as length and density.

[0020] As described above, as a result of the optimized structure of the aerosol cooling element, effective cooling and nucleation of the aerosol can be achieved over a relatively short distance, such that the length of the aerosol cooling element can be reduced compared to prior art articles. This then allows for an increase in the length of the mouthpiece element while maintaining the same overall length of the aerosol generating article. As will be described in more detail below, the inclusion of a relatively long mouthpiece provides optimal aerosol filtration.

[0021] Furthermore, this combination of elements in the aerosol generating article according to the present invention has been found to advantageously provide consumers with improved tactile feedback during use. The hollow tubular segment of the aerosol cooling element provides relatively high rigidity compared to the mouthpiece, and therefore consumers can feel the junction between the mouthpiece and the aerosol cooling element more clearly. This allows consumers to position their lips appropriately on the aerosol generating article, minimizing the risk of blocking the provided vents.

[0022] The combination of a relatively long mouthpiece element and an aerosol cooling element in the form of a hollow tubular segment is also advantageously found to provide a more rigid mouthpiece element in the aerosol generating article according to the present invention. Thus, the aerosol generating article can provide greater resistance to radial compression at positions toward the downstream end of the article. Advantageously, this benefit can be provided without affecting the overall length of the article, so as to maintain an overall length consistent with existing aerosol generating articles.

[0023] Providing a more rigid mouthpiece element has been found to contribute to a more efficient smoking action by the consumer, allowing for further optimization of aerosol delivery. Furthermore, by providing a more rigid mouthpiece element proximal to the aerosol cooling element, the risk of deformation of the aerosol cooling element during use can be significantly reduced. This is important because deformation of the aerosol cooling element is undesirable due to the adverse effects such deformation may have on aerosol formation.

[0024] The mouthpiece element is typically more elastic to deformation than other elements provided downstream of the rod of the aerosol-generating substrate. Therefore, increasing the length of the mouthpiece element relative to the length of the intermediate hollow section has been found to provide an improved grip for the consumer. Insertion of the aerosol-generating article into the heating device is also facilitated.

[0025] Increasing the length of the mouthpiece element offers several other technical advantages. Using a longer mouthpiece element can provide higher filtration and removal of undesirable aerosol components such as phenol, thereby enabling the delivery of higher-quality aerosols. Furthermore, the use of a longer mouthpiece element allows for more complex mouthpiece structures, as there is more space to incorporate mouthpiece components such as capsules, threads, and restrictors.

[0026] As described, the relatively long mouthpiece element of the aerosol generating article according to the present invention may be particularly effective when combined with an intermediate hollow section having a reduced length. The reduction in the length of the hollow intermediate section relative to the mouthpiece element may be advantageously provided by reducing the length of the aerosol cooling element, as will be described in more detail below. The aerosol cooling element typically has lower resistance to deformation than the mouthpiece element. The reduction in the length of the aerosol cooling element further reduces the risk of deformation of the aerosol generating article due to compression during use. Furthermore, the reduction in the length of the aerosol cooling element may offer a cost advantage to the manufacturer, since the cost of the hollow tubular segment is typically higher per unit length than the cost of the mouthpiece element.

[0027] According to the present invention, an aerosol generating article is provided for generating an inhalable aerosol upon heating. The aerosol generating article comprises a rod of an aerosol generating substrate. The aerosol generating article further comprises a downstream section located downstream of the rod of the aerosol generating substrate. The downstream section may include one or more downstream elements.

[0028] In the aerosol generating article according to the present invention, the downstream section comprises a mouthpiece element. The mouthpiece element may extend entirely to the oral end of the aerosol generating article. The downstream section further comprises an intermediate hollow section between the mouthpiece element and the rod of the aerosol generating substrate. The intermediate hollow section comprises an aerosol cooling element. The aerosol cooling element comprises a hollow tubular segment. The intermediate hollow section may further comprise a support element which may include the hollow tubular segment.

[0029] In some embodiments, the aerosol generating article may have a ventilation zone located along the downstream section. More specifically, the aerosol generating article may have a ventilation zone located along the aerosol cooling element. In a preferred embodiment, the aerosol cooling element includes or is in the form of a hollow tubular segment, and the ventilation zone is provided at a location along the hollow tubular segment of the aerosol cooling element.

[0030] The aerosol generating article may further comprise 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 comprises an upstream element located immediately upstream of the rod of the aerosol generating substrate.

[0031] The aerosol generating article may further include a susceptor element within the aerosol generating substrate. In some embodiments, the susceptor element may be an elongated susceptor element. In preferred embodiments, the susceptor element extends longitudinally within the aerosol generating substrate.

[0032] These elements of aerosol-generating articles are described in more detail below.

[0033] As defined above, the downstream section of the aerosol generating article of the present invention comprises a mouthpiece element. The mouthpiece element is preferably located at the downstream end or mouth end of the aerosol generating article. The mouthpiece element preferably comprises at least one mouthpiece filter segment for filtering aerosols generated from the aerosol generating substrate. For example, the mouthpiece element may comprise one or more segments of a fibrous filter material. Suitable fibrous filter materials are known to those skilled in the art. Particularly preferably, at least one mouthpiece filter segment comprises a cellulose acetate filter segment formed from cellulose acetate tow.

[0034] In certain preferred embodiments, the mouthpiece element consists of a single mouthpiece filter segment. In alternative embodiments, the mouthpiece element comprises two or more mouthpiece filter segments aligned axially with end-to-end contact with one another.

[0035] In certain embodiments of the present invention, the downstream section may have an oral end cavity at the downstream end of the mouthpiece element as described above. The oral end cavity may be defined by a hollow tubular element provided at the downstream end of the mouthpiece. Alternatively, the oral end cavity may be defined by an outer wrapper of the mouthpiece element, which extends downstream from the mouthpiece element.

[0036] The mouthpiece element may optionally contain flavoring agents that can be provided in any preferred form. For example, the mouthpiece element may contain one or more capsules, flavoring agent beads or granules, or one or more flavoring threads or filaments.

[0037] In the aerosol generating article according to the present invention, the mouthpiece element forms part of the downstream section and is therefore located downstream of the rod of the aerosol generating substrate.

[0038] Preferably, the mouthpiece element is located immediately downstream of the aerosol cooling element. For example, the mouthpiece element may be in contact with the downstream end of the aerosol cooling element.

[0039] Preferably, the mouthpiece element has a low particle filtration efficiency.

[0040] Preferably, the mouthpiece is formed from segments of fibrous filter material.

[0041] The mouthpiece element is preferably surrounded by a plug wrap. Preferably, the mouthpiece element is not ventilated so that air does not enter the aerosol-generating article along the mouthpiece element.

[0042] The mouthpiece element is preferably connected by a tip wrapper to one or more adjacent upstream components of the aerosol-generating article.

[0043] Preferably, the mouthpiece element has an RTD of less than about 25 mmH2O. More preferably, the mouthpiece element has an RTD of less than about 20 mmH2O. Even more preferably, the mouthpiece element has an RTD of less than about 15 mmH2O.

[0044] A RTD value of approximately 10 mmH2O to approximately 15 mmH2O is particularly preferable, as it is expected that a mouthpiece element having one such RTD will contribute minimally to the overall RTD of the aerosol-generating article and therefore will not substantially filter the aerosol delivered to the consumer.

[0045] The mouthpiece element preferably has an outer diameter approximately equal to the outer diameter of the aerosol generating article. The mouthpiece element may have an outer diameter of about 5 mm to about 10 mm, or about 6 mm to about 8 mm. In a preferred embodiment, the mouthpiece element has an outer diameter of about 7.2 mm.

[0046] According to the present invention, the mouthpiece element preferably has a length of at least about 10 millimeters, more preferably at least about 11 millimeters, and more preferably at least about 12 millimeters. Alternatively, or additionally, the mouthpiece element preferably has a length of less than about 25 millimeters, more preferably less than about 20 millimeters, and more preferably less than about 15 millimeters.

[0047] In some embodiments, the mouthpiece element preferably has a length of about 10 mm to about 25 mm, more preferably about 10 mm to about 20 mm, and even more preferably about 10 mm to about 15 mm. In other embodiments, the mouthpiece element preferably has a length of about 11 mm to about 25 mm, more preferably about 11 mm to about 20 mm, and even more preferably about 11 mm to about 20 mm. In other embodiments, the mouthpiece element preferably has a length of about 12 mm to about 25 mm, more preferably about 12 mm to about 20 mm, and even more preferably about 12 mm to about 20 mm.

[0048] In a preferred embodiment, the mouthpiece element has a length of approximately 12 millimeters.

[0049] In the aerosol generating article of the present invention, the mouthpiece element is relatively longer compared to the mouthpiece elements provided in prior art articles. As described above, the provision of a relatively long mouthpiece element in the aerosol generating article of the present invention may provide several benefits to consumers.

[0050] In a particularly preferred embodiment of the present invention, a mouthpiece element having a length of at least 10 millimeters is combined with a relatively short aerosol cooling element, for example, an aerosol cooling element having a length of less than 10 millimeters. This combination has been found to provide a more rigid mouthpiece element that reduces the risk of deformation of the aerosol cooling element during use and contributes to a more efficient smoking action by the consumer.

[0051] The length of the mouthpiece element is preferably at least 0.4 times the total length of the intermediate hollow section, preferably at least 0.5 times the length of the intermediate hollow section, more preferably at least 0.6 times the length of the intermediate hollow section, and more preferably at least 0.7 times the length of the intermediate hollow section. Therefore, the ratio between the length of the mouthpiece element and the total length of the intermediate hollow section is at least about 0.4, preferably at least about 0.5, more preferably at least about 0.6, and most preferably at least about 0.7.

[0052] The ratio between the length of the mouthpiece element and the length of the rod of the aerosol generating substrate can be approximately 0.5 to approximately 1.5.

[0053] The ratio between the length of the mouthpiece element and the length of the rod of the aerosol generating substrate is preferably at least about 0.6, more preferably at least about 0.7, and even more preferably at least about 0.8. In a preferred embodiment, the ratio between the length of the mouthpiece element and the length of the rod of the aerosol generating substrate is less than about 1.4, more preferably less than about 1.3, and even more preferably less than about 1.2.

[0054] In some embodiments, the ratio between the length of the mouthpiece element and the length of the rod of the aerosol generating substrate is about 0.6 to about 1.4, preferably about 0.7 to about 1.4, and more preferably about 0.8 to about 1.4. In other embodiments, the ratio between the length of the mouthpiece element and the length of the rod of the aerosol generating substrate is about 0.6 to about 1.3, preferably about 0.7 to about 1.3, and more preferably about 0.8 to about 1.3. In further embodiments, the ratio between the length of the mouthpiece element and the length of the rod of the aerosol generating substrate is about 0.6 to about 1.2, preferably about 0.7 to about 1.2, and more preferably about 0.8 to about 1.2.

[0055] In a particularly preferred embodiment, the ratio between the length of the mouthpiece element and the length of the rod of the aerosol generating substrate is about 1.

[0056] The ratio between the length of the mouthpiece element and the total length of the aerosol-generating article substrate can be approximately 0.2 to approximately 0.35.

[0057] Preferably, the ratio of the length of the mouthpiece element to the total length of the aerosol-generating article substrate is at least about 0.22, more preferably at least about 0.24, and even more preferably at least about 0.26. Preferably, the ratio of the length of the mouthpiece element to the total length of the aerosol-generating article substrate is less than about 0.34, more preferably less than about 0.32, and even more preferably less than about 0.3.

[0058] In some embodiments, the ratio of the length of the mouthpiece element to the total length of the aerosol-generating article substrate is preferably about 0.22 to about 0.34, more preferably about 0.24 to about 0.34, and even more preferably about 0.26 to about 0.34. In other embodiments, the ratio of the length of the mouthpiece element to the total length of the aerosol-generating article substrate is preferably about 0.22 to about 0.32, more preferably about 0.24 to about 0.32, and even more preferably about 0.26 to about 0.32. In further embodiments, the ratio of the length of the mouthpiece element to the total length of the aerosol-generating article substrate is preferably about 0.22 to about 0.3, more preferably about 0.24 to about 0.3, and even more preferably about 0.26 to about 0.3.

[0059] In a particularly preferred embodiment, the ratio between the length of the mouthpiece element and the total length of the aerosol-generating article substrate is about 0.27.

[0060] As described above, the downstream section of the aerosol generating article according to the present invention further comprises an intermediate hollow section having an aerosol cooling element that is aligned with the rods of the aerosol generating substrate and positioned downstream of the rods of the aerosol generating substrate.

[0061] The aerosol cooling element is positioned substantially aligned with the rod. This means that the length dimension of the aerosol cooling element is positioned approximately parallel to the longitudinal direction of the rod and the article, for example, within ±10 degrees of parallel to the longitudinal direction of the rod. In a preferred embodiment, the aerosol cooling element extends along the longitudinal axis of the rod.

[0062] In the aerosol generating article according to the present invention, the aerosol cooling element is in the form of a hollow tubular segment defining a cavity that extends throughout from the upstream end to the downstream end of the aerosol cooling element. Preferably, a ventilation zone is provided along the hollow tubular segment.

[0063] The inventors found that satisfactory cooling of the aerosol flow generated in conjunction with the heating of an aerosol generating substrate and drawn out through one of such aerosol cooling elements can be achieved by providing a ventilation zone along a hollow tubular segment. Furthermore, the inventors found that it may be possible to counteract the effects of increased aerosol dilution caused by the mixing of ventilation air into the article, particularly by locating the ventilation zone at a precisely defined location along the length of the aerosol cooling element, and preferably by utilizing a hollow tubular segment having a predetermined wall thickness or internal volume, as described in more detail below.

[0064] While not bound by theory, as the aerosol moves toward the mouthpiece segment, the introduction of ventilation air rapidly reduces the temperature of the aerosol flow. This allows the ventilation air to enter the aerosol flow relatively close to the upstream end of the aerosol cooling element (i.e., close enough to the susceptor element extending within the rod of the aerosol generating substrate, which is the heat source in use), achieving dramatic cooling of the aerosol flow, which is thought to have a favorable effect on the condensation and nucleation of aerosol particles. As a result, the overall ratio of the aerosol particle phase to the aerosol gas phase may be increased compared to existing non-ventilated aerosol generating articles.

[0065] Simultaneously, by maintaining a relatively low thickness of the peripheral walls of the hollow tubular segment, it is ensured that the overall internal volume of the hollow tubular segment is effectively maximized, so that the aerosol components become available for the aerosol to initiate the nucleation process as soon as they leave the rod of the aerosol generating substrate, and that the cross-sectional area of ​​the hollow tubular segment is effectively maximized, while at the same time ensuring that the hollow tubular segment has the structural strength necessary to prevent the collapse of the aerosol generating article and provide some support to the rod of the aerosol generating substrate, and that the RTD of the hollow tubular segment is minimized. A larger value of the cross-sectional area of ​​the cavity of the hollow tubular segment is understood to be associated with a reduced velocity of the aerosol flow moving along the aerosol generating article, and is further expected to work favorably for nucleation. Furthermore, by utilizing a hollow tubular segment with a relatively low thickness, it is possible to substantially prevent the diffusion of the venting air before it comes into contact with and mixes with the aerosol flow, and is further understood to work favorably for the nucleation phenomenon. In practice, it is possible to improve the cooling effect on the formation of new aerosol particles by providing more controllable and localized cooling of the flow of volatile seeds.

[0066] The aerosol cooling element preferably has an outer diameter that is approximately equal to the outer diameter of the rod of the aerosol generating substrate and the outer diameter of the aerosol generating article.

[0067] The aerosol cooling element may have an outer diameter of 5 to 12 mm, for example, 5 to 10 mm, or 6 to 8 mm. In a preferred embodiment, the aerosol cooling element has an outer diameter of 7.2 mm plus or minus 10 percent.

[0068] The hollow tubular segment of the aerosol cooling element preferably has an inner diameter of at least about 2 mm. More preferably, the hollow tubular segment of the aerosol cooling element has an inner diameter of at least about 2.5 mm. Even more preferably, the hollow tubular segment of the aerosol cooling element has an inner diameter of at least about 3 mm.

[0069] According to the present invention, the hollow tubular segment of the aerosol cooling element has a wall thickness of less than about 2.5 mm, preferably less than about 2.2 mm. In a preferred embodiment, the hollow tubular segment of the aerosol cooling element has a wall thickness of about 2 mm.

[0070] The hollow tubular segment of the aerosol cooling element preferably has a wall thickness of at least about 1.5 mm, and more preferably at least about 1.75 mm. The hollow tubular segment therefore preferably has a wall thickness of about 1.5 mm to about 2.5 mm, or about 1.75 mm to about 2.5 mm, or about 1.75 mm to about 2.2 mm, or about 2 mm.

[0071] Preferably, the aerosol cooling element has a length of at least about 5 mm, more preferably at least about 6 mm, and more preferably at least about 7 mm.

[0072] According to the present invention, the aerosol cooling element has a length of less than about 10 millimeters, preferably less than about 9 millimeters.

[0073] In some embodiments, the aerosol cooling element has a length of about 5 mm to about 10 mm, preferably about 6 mm to about 10 mm, and more preferably about 7 mm to about 10 mm. In other embodiments, the aerosol cooling element has a length of about 5 mm to about 9 mm, preferably about 6 mm to about 9 mm, and more preferably about 7 mm to about 9 mm. For example, in one particularly preferred embodiment, the aerosol cooling element has a length of 8 mm.

[0074] In the aerosol generating article according to the present invention, the aerosol cooling element is therefore relatively shorter in length compared to the aerosol cooling element of the prior art aerosol generating article. The reduction in the length of the aerosol cooling element is made possible by optimizing the effect of the hollow tubular segment forming the aerosol cooling element in aerosol cooling and nucleation. The reduction in the length of the aerosol cooling element favorably reduces the risk of deformation of the aerosol generating article due to compression during use, as the aerosol cooling element is typically less resistant to deformation than a mouthpiece. Furthermore, the reduction in the length of the aerosol cooling element may offer a cost advantage to the manufacturer, as the cost of the hollow tubular segment is typically higher per unit length than the cost of other elements such as mouthpiece elements.

[0075] The ratio between the length of the aerosol cooling element and the length of the rod of the aerosol generating substrate can be approximately 0.25 to approximately 1.

[0076] Preferably, the ratio between the length of the aerosol cooling element and the length of the rod of the aerosol generating substrate is at least about 0.3, more preferably at least about 0.4, and even more preferably at least about 0.5. In a preferred embodiment, the ratio between the length of the aerosol cooling element and the length of the rod of the aerosol generating substrate is less than about 0.9, more preferably less than about 0.8, and even more preferably less than about 0.7.

[0077] In some embodiments, the ratio between the length of the aerosol cooling element and the length of the rod of the aerosol generating substrate is about 0.3 to about 0.9, preferably about 0.4 to about 0.9, and more preferably about 0.5 to about 0.9. In other embodiments, the ratio between the length of the aerosol cooling element and the length of the rod of the aerosol generating substrate is about 0.3 to about 0.8, preferably about 0.4 to about 0.8, and more preferably about 0.5 to about 0.8. In further embodiments, the ratio between the length of the aerosol cooling element and the length of the rod of the aerosol generating substrate is about 0.3 to about 0.7, preferably about 0.4 to about 0.7, and more preferably about 0.5 to about 0.7.

[0078] In a particularly preferred embodiment, the ratio between the length of the aerosol cooling element and the length of the rod of the aerosol generating substrate is about 0.66.

[0079] Preferably, the ratio of the length of the aerosol cooling element to the total length of the aerosol generating article substrate is at least about 0.13, more preferably at least about 0.14, and even more preferably at least about 0.15. Preferably, the ratio of the length of the aerosol cooling element to the total length of the aerosol generating article substrate is less than about 0.3, more preferably less than about 0.25, and even more preferably less than about 0.20.

[0080] In some embodiments, the ratio of the length of the aerosol cooling element to the total length of the aerosol generating article substrate is preferably about 0.13 to about 0.3, more preferably about 0.14 to about 0.3, and even more preferably about 0.15 to about 0.3. In other embodiments, the ratio of the length of the aerosol cooling element to the total length of the aerosol generating article substrate is preferably about 0.13 to about 0.25, more preferably about 0.14 to about 0.25, and even more preferably about 0.15 to about 0.25. In further embodiments, the ratio of the length of the aerosol cooling element to the total length of the aerosol generating article substrate is preferably about 0.13 to about 0.2, more preferably about 0.14 to about 0.2, and even more preferably about 0.15 to about 0.2.

[0081] In a particularly preferred embodiment, the ratio between the length of the aerosol cooling element and the total length of the aerosol generating article substrate is about 0.18.

[0082] The length of the mouthpiece element is preferably at least 1 millimeter greater than the length of the aerosol cooling element, more preferably at least 2 millimeters greater than the length of the aerosol cooling element, and more preferably at least 3 millimeters greater than the length of the aerosol cooling element. The reduction in the length of the aerosol cooling element as described above can advantageously allow for an increase in the length of other elements of the aerosol generating article, such as the mouthpiece element. The potential technical benefits of providing a relatively long mouthpiece element are described above.

[0083] The ratio between the length of the aerosol cooling element and the length of the rod of the aerosol generating substrate can be approximately 0.25 to approximately 1.

[0084] Preferably, the ratio between the length of the aerosol cooling element and the length of the rod of the aerosol generating substrate is at least about 0.3, more preferably at least about 0.4, and even more preferably at least about 0.5. In a preferred embodiment, the ratio between the length of the aerosol cooling element and the length of the rod of the aerosol generating substrate is less than about 0.9, more preferably less than about 0.8, and even more preferably less than about 0.7.

[0085] In some embodiments, the ratio between the length of the aerosol cooling element and the length of the rod of the aerosol generating substrate is about 0.3 to about 0.9, preferably about 0.4 to about 0.9, and more preferably about 0.5 to about 0.9. In other embodiments, the ratio between the length of the aerosol cooling element and the length of the rod of the aerosol generating substrate is about 0.3 to about 0.8, preferably about 0.4 to about 0.8, and more preferably about 0.5 to about 0.8. In further embodiments, the ratio between the length of the aerosol cooling element and the length of the rod of the aerosol generating substrate is about 0.3 to about 0.7, preferably about 0.4 to about 0.7, and more preferably about 0.5 to about 0.7.

[0086] In a particularly preferred embodiment, the ratio between the length of the aerosol cooling element and the length of the rod of the aerosol generating substrate is about 0.66.

[0087] The ratio between the length of the aerosol cooling element and the total length of the aerosol generating article substrate can be approximately 0.125 to approximately 0.375.

[0088] Preferably, the ratio of the length of the aerosol cooling element to the total length of the aerosol generating article substrate is at least about 0.13, more preferably at least about 0.14, and even more preferably at least about 0.15. Preferably, the ratio of the length of the aerosol cooling element to the total length of the aerosol generating article substrate is less than about 0.3, more preferably less than about 0.25, and even more preferably less than about 0.20.

[0089] In some embodiments, the ratio of the length of the aerosol cooling element to the total length of the aerosol generating article substrate is preferably about 0.13 to about 0.3, more preferably about 0.14 to about 0.3, and even more preferably about 0.15 to about 0.3. In other embodiments, the ratio of the length of the aerosol cooling element to the total length of the aerosol generating article substrate is preferably about 0.13 to about 0.25, more preferably about 0.14 to about 0.25, and even more preferably about 0.15 to about 0.25. In further embodiments, the ratio of the length of the aerosol cooling element to the total length of the aerosol generating article substrate is preferably about 0.13 to about 0.2, more preferably about 0.14 to about 0.2, and even more preferably about 0.15 to about 0.2.

[0090] In a particularly preferred embodiment, the ratio between the length of the aerosol cooling element and the total length of the aerosol generating article substrate is about 0.18.

[0091] The length of the mouthpiece element is preferably at least 1 millimeter greater than the length of the aerosol cooling element, more preferably at least 2 millimeters greater than the length of the aerosol cooling element, and more preferably at least 3 millimeters greater than the length of the aerosol cooling element. The reduction in the length of the aerosol cooling element as described above can advantageously allow for an increase in the length of other elements of the aerosol generating article, such as the mouthpiece element. The potential technical benefits of providing a relatively long mouthpiece element are described above.

[0092] In the aerosol-generating article according to the present invention, the aerosol cooling element preferably has an average radial hardness of at least about 80 percent, more preferably at least about 85 percent, and even more preferably at least about 90 percent. Therefore, the aerosol cooling element can provide the aerosol-generating article with a desired hardness level.

[0093] If desired, the radial hardness of the aerosol cooling element of the aerosol generating article according to the present invention may be further increased by surrounding the aerosol cooling element with a rigid plug wrap, such as a plug wrap having a basis weight of at least about 80 grams / square meter (gsm), at least about 100 gsm, or at least about 110 gsm.

[0094] As used herein, the term “radial hardness” of an element refers to its resistance to compression in a direction transverse to the longitudinal axis of the element. The radial hardness of an aerosol-generating article around an element can be determined by applying a load across the article at the element's location, transverse to the longitudinal axis of the article, and by measuring the average (mean) of the compressed diameter of the article. Radial hardness is given by: TIFF0007851252000001.tif2061D S D is the original (uncompressed) diameter. dThis represents the diameter after applying a set load over a set duration. The harder the material, the closer the hardness approaches 100 percent.

[0095] To determine the hardness of a portion of an aerosol article (such as an aerosol cooling element provided in the form of a hollow tube segment), the aerosol-generating articles should be aligned parallel to each other in a plane, and the same portion of each aerosol-generating article being tested should be subjected to a set load for a set duration. This test is performed using a known DD60A Densimeter apparatus (manufactured and sold by Heinr Borgwaldt GmbH, Germany), which is fitted with a measuring head for aerosol-generating articles such as cigarettes, and also includes an aerosol-generating article container.

[0096] A load is applied using two load-applying cylindrical rods that extend across the diameter of all aerosol-generating articles at once. According to the standard test method for this device, the test should be conducted so that 20 contact points are created between the aerosol-generating articles and the load-applying cylindrical rods. In some cases, the hollow tube segment being tested may be long enough so that only 10 aerosol-generating articles are needed to form 20 contact points where each smoking article contacts both load-applying rods (as they are long enough to extend between both rods). In other cases, where the support elements are excessively short to achieve this, 20 aerosol-generating articles should be used to form 20 contact points, as will be further discussed below, with each aerosol-generating article contacting only one of the load-applying rods.

[0097] Two additional fixed cylindrical rods are positioned beneath the aerosol-generating article to support it and to counteract the load applied by each of the load-applying cylindrical rods.

[0098] The standard operating procedure for such a device involves applying an overall load of 2 kg for 20 seconds. After 20 seconds (while the load is still applied to the smoking article), the pressure on the load-applying cylindrical rod is determined and then used to calculate the hardness from the equation described above. The temperature is maintained within the range of 22 degrees Celsius ± 2 degrees. The above test is called the DD60A test. The standard method for measuring filter hardness is when the aerosol-generating article has not yet been consumed. Additional information regarding the measurement of mean radial hardness can be found, for example, in U.S. Patent Application No. 2016 / 0128378.

[0099] The aerosol cooling element may be formed from any suitable material or combination of materials. For example, the aerosol cooling 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 sulfuric acid paper), and polymer materials (such as low-density polyethylene (LDPE)). Other suitable materials include polyhydroxyalkanoate (PHA) fibers.

[0100] In a preferred embodiment, the aerosol cooling element is formed from cellulose acetate.

[0101] Preferably, the hollow tubular segments of the aerosol cooling element are adapted to generate RTDs of approximately 0 mmH2O (approximately 0 Pa) to approximately 20 mmH2O (approximately 100 Pa), more preferably approximately 0 mmH2O (approximately 0 Pa) to approximately 10 mmH2O (approximately 100 Pa).

[0102] In the aerosol-generating article according to the present invention, the overall RTD of the article depends essentially on the RTD of the rod, and optionally on the RTD of the mouthpiece and / or upstream plug. This is because the hollow tubular segments of the aerosol cooling element and the hollow tubular segments of the support element are substantially empty and therefore contribute only substantially slightly to the overall RTD of the aerosol-generating article.

[0103] The ventilation zone comprises multiple perforations running through the peripheral wall of the aerosol cooling element. Preferably, the ventilation zone includes at least one row of perforations around the periphery. In some embodiments, the ventilation zone may include two rows of perforations around the periphery. For example, the perforations may be formed online during the manufacturing of the aerosol-generating article. Each row of perforations around the periphery preferably contains 8 to 30 perforations.

[0104] The aerosol-generating article according to the present invention may have a ventilation level of at least about 5 percent.

[0105] The term "ventilation level" is used throughout this specification to mean the volume ratio of the airflow entering the aerosol-generating article through the ventilation zone (ventilation airflow) to the sum of the aerosol airflow and the ventilation airflow. A higher ventilation level results in greater dilution of the aerosol flow delivered to the consumer.

[0106] Aerosol-generating articles may typically have a ventilation level of at least about 10 percent, preferably at least about 15 percent, and more preferably at least about 20 percent.

[0107] In a preferred embodiment, the aerosol-generating article has a ventilation level of at least about 25 percent. Preferably, the aerosol-generating article has a ventilation level of less than about 60 percent. Preferably, the aerosol-generating article according to the present invention has a ventilation level of about 45 percent or less. More preferably, the aerosol-generating article according to the present invention has a ventilation level of about 40 percent or less, and even more preferably about 35 percent or less.

[0108] In a particularly preferred embodiment, the aerosol-generating article has a ventilation level of about 30 percent. In some embodiments, the aerosol-generating article has a ventilation level of about 20 percent to about 60 percent, preferably about 20 percent to about 45 percent, and more preferably about 20 percent to about 40 percent. In other embodiments, the aerosol-generating article has a ventilation level of about 25 percent to about 60 percent, preferably about 25 percent to about 45 percent, and more preferably about 25 percent to about 40 percent. In a further embodiment, the aerosol-generating article has a ventilation level of about 30 percent to about 60 percent, preferably about 30 percent to about 45 percent, and more preferably about 30 percent to about 40 percent.

[0109] In a particularly preferred embodiment, the aerosol-generating article has a permeability level of about 28 percent to about 42 percent. In some particularly preferred embodiments, the aerosol-generating article has a permeability level of about 30 percent.

[0110] While not wishing to be constrained by theory, the inventors found that the temperature reduction resulting from introducing colder outside air into the hollow tubular segment through a ventilation zone may have a favorable effect on the nucleation and growth of aerosol particles.

[0111] The formation of aerosols from gaseous mixtures containing various chemical species depends on the delicate interactions between nucleation, evaporation, condensation, and even fusion, which explain changes in vapor concentration, temperature, and velocity fields. The so-called classical nucleation theory is based on the assumption that some molecules in the gas phase are large enough to remain coherent for a long time with a sufficient probability (e.g., a 50 / 50 probability). These molecules represent a kind of critical threshold molecular cluster within transient molecular aggregates, meaning that smaller molecular clusters generally decompose into the gas phase somewhat more readily, while larger clusters generally grow more readily. These critical clusters are identified as the primary nucleation cores from which droplets are expected to grow due to the condensation of molecules from the vapor. The newly nucleated, untreated droplet is assumed to appear with a certain intrinsic diameter and then grow by several orders of magnitude. This can be facilitated and enhanced by the rapid cooling of the surrounding vapor, which induces condensation. In this regard, it is helpful to keep in mind that evaporation and condensation are two aspects of the same mechanism: the transfer of mass between liquid and gas. Evaporation involves net mass transfer from the liquid droplet phase to the gas phase, while condensation is net mass transfer from the gas phase to the liquid droplet phase. Due to evaporation (or condensation), the liquid droplet shrinks (or grows), but the number of droplets does not change.

[0112] In this scenario (and if the scenario is further complicated by fusion phenomena), the temperature and rate of cooling may play a crucial role in determining how the system responds. Generally, because the nucleation process is typically nonlinear, different cooling rates may lead to significantly different temperature behavior with respect to liquid phase (droplet) formation. While we do not wish to be bound by theory, we assume that cooling can result in a rapid increase in the number of droplet condensations, followed by a short, strong increase in this growth (nucleation burst). This nucleation burst is likely to be more pronounced at lower temperatures. Furthermore, faster cooling rates may favor the early initiation of nucleation. In contrast, a decrease in the cooling rate is likely to have a favorable effect on the final size that the aerosol droplets eventually reach.

[0113] Therefore, the rapid cooling induced by introducing outside air into the hollow tubular segment through the ventilation zone can be used to favor the advantageous nucleation and growth of aerosol droplets. However, at the same time, introducing outside air into the hollow tubular segment has the direct disadvantage of diluting the aerosol flow delivered to the consumer.

[0114] The inventors were surprised to find that the dilution effect on aerosols (which can be evaluated by measuring its effect on the delivery of aerosol-forming substances (such as glycerol) contained in the aerosol-generating substrate) is favorably minimized at permeability levels within the aforementioned range. In particular, permeability levels of 25 to 50 percent, and more preferably 28 to 42 percent, were found to lead to particularly satisfactory values ​​of glycerol delivery. At the same time, the degree of nucleation, and consequently the delivery of nicotine and aerosol-forming substances (e.g., glycerol), is enhanced.

[0115] The inventors were surprised to find that the favorable effect of enhanced nucleation, facilitated by rapid cooling induced by the introduction of aeration air into the article, significantly counteracts the undesirable effect of dilution. Therefore, satisfactory values ​​of aerosol delivery are consistently achieved by the aerosol-generating article according to the present invention.

[0116] This is particularly advantageous for “short” aerosol-generating articles, such as when the length of the rod of the aerosol-generating substrate is less than about 40 millimeters, preferably less than 25 millimeters, and even more preferably less than 20 millimeters, or when the total length of the aerosol-generating article is less than about 70 millimeters, preferably less than about 60 millimeters, and even more preferably less than 50 millimeters. As is understood, in such aerosol-generating articles, there is little time and space for aerosol formation and little time and space for the particulate phase of the aerosol to become available for delivery to the consumer.

[0117] Furthermore, since the vented hollow tubular segments do not substantially contribute to the overall RTD of the aerosol-generating article, the overall RTD of the article can be advantageously fine-tuned in the aerosol-generating article according to the present invention by adjusting the length and density of the rods of the aerosol-generating substrate, or the length and optionally the length and density of the segments of the filter material forming part of the mouthpiece, or the length and density of the segments of the filter material provided upstream of the aerosol-generating substrate and susceptor element. Thus, it is possible to consistently and very accurately manufacture aerosol-generating articles having a predetermined RTD so that a satisfactory level of RTD can be provided to consumers, even in the presence of venting.

[0118] In some embodiments, the aerosol-generating article may further comprise additional cooling elements that define multiple longitudinally extending channels, such as by making a high surface area available for heat exchange. In other words, one such additional cooling element is adapted to function substantially as a heat exchanger. Multiple longitudinally extending channels may be defined by a sheet material that has been processed by crimping, assembling, or folding to form the channels. Multiple longitudinally extending channels may be defined by a single sheet that has been processed by crimping, assembling, or folding to form the multiple channels. The sheet may also be crimped before being crimped, assembling, or folded. Alternatively, multiple longitudinally extending channels may be defined by multiple sheets that have been crimped, crimped, assembling, or folded to form the multiple channels. In some embodiments, a plurality of longitudinally extending channels may be defined by a plurality of sheets that are crimped, pleated, assembled, or folded, i.e., brought into an overlay arrangement and then defined by two or more sheets that are crimped, pleated, assembled, or folded as a single entity. As used herein, the term “sheet” means a thin, layered element having a width and length substantially greater than its thickness.

[0119] As used herein, the term “longitudinal direction” refers to the direction extending along or parallel to the cylindrical axis of the rod. As used herein, the term “crimped” means a sheet having multiple substantially parallel ridges or undulations. When an aerosol-generating article is assembled, it is preferable that the substantially parallel ridges or undulations extend longitudinally with respect to the rod. As used herein, the terms “assembled,” “crimped,” or “folded” mean that a sheet of material is spiraled, folded, or otherwise compressed or shrunk substantially transversely with respect to the cylindrical axis of the rod. The sheet may be crimped before being assembled, crimped, or folded. The sheet may be assembled, crimped, or folded without prior crimping.

[0120] Such an additional cooling element may have a total surface area of ​​approximately 300 square millimeters per millimeter of length to approximately 1,000 square millimeters per millimeter of length.

[0121] The additional cooling element preferably provides low draw resistance to the passage of air through it. Preferably, the additional cooling element does not substantially affect the draw resistance of the aerosol-generating article. To achieve this, it is preferable that the longitudinal porosity is greater than 50 percent and that the airflow path through the additional cooling element is relatively unrestricted. The longitudinal porosity of the additional cooling element can be defined by the ratio of the cross-sectional area of ​​the material forming the additional cooling element to the internal cross-sectional area of ​​the aerosol-generating article at the location of the portion containing the additional cooling element.

[0122] The additional cooling element preferably includes a sheet material selected from the group consisting of metal foil, polymer sheets, and substantially non-porous paper or cardboard. In some embodiments, the aerosol cooling element may include 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. In a particularly preferred embodiment, the additional cooling element includes a sheet of PLA.

[0123] As described above, the intermediate hollow section preferably further comprises a support element aligned with the rod of the aerosol generating substrate and positioned downstream of the rod of the aerosol generating substrate. In particular, the support element may be located immediately downstream of the rod of the aerosol generating substrate, or it may be adjacent to the rod of the aerosol generating substrate.

[0124] 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 sulfuric acid paper), and polymer materials (such as low-density polyethylene (LDPE)). In a preferred embodiment, the support element is formed from cellulose acetate. Other suitable materials include polyhydroxyalkanoate (PHA) fibers.

[0125] The support element may include hollow tubular segments. In a preferred embodiment, the support element includes a hollow cellulose acetate tube.

[0126] The support elements are preferably positioned substantially aligned with the rod. This means that the length dimension of the support elements is positioned substantially parallel to the longitudinal direction of the rod and the article, for example, within ±10 degrees from parallel to the longitudinal direction of the rod. In a preferred embodiment, the support elements extend along the longitudinal axis of the rod.

[0127] The support element preferably has an outer diameter that is approximately equal to the outer diameter of the rod of the aerosol generating substrate and the outer diameter of the aerosol generating article.

[0128] The support element may have an outer diameter of 5 mm to 12 mm, for example, 5 mm to 10 mm, or 6 mm to 8 mm. In a preferred embodiment, the support element has an outer diameter of 7.2 mm ± 10 percent.

[0129] The peripheral wall of the support element may have a thickness of at least 1 millimeter, preferably at least about 1.5 millimeters, and more preferably at least about 2 millimeters.

[0130] The support element may have a length of approximately 5 mm to approximately 15 mm.

[0131] The support element is preferably at least about 6 millimeters in length, and more preferably at least about 7 millimeters in length.

[0132] In a preferred embodiment, the support element has a length of less than about 12 millimeters, more preferably less than about 10 millimeters.

[0133] In some embodiments, the support element has a length of about 5 mm to about 15 mm, preferably about 6 mm to about 15 mm, and more preferably about 7 mm to about 15 mm. In other embodiments, the support element has a length of about 5 mm to about 12 mm, preferably about 6 mm to about 12 mm, and more preferably about 7 mm to about 12 mm. In further embodiments, the support element has a length of about 5 mm to about 10 mm, preferably about 6 mm to about 10 mm, and more preferably about 7 mm to about 10 mm.

[0134] In a preferred embodiment, the support element has a length of about 8 millimeters.

[0135] Preferably, the intermediate hollow section has a total length of about 18 mm or less, preferably about 17 mm or less, and more preferably about 16 mm or less.

[0136] The ratio between the length of the support element and the length of the rod of the aerosol generating substrate can be approximately 0.25 to approximately 1.

[0137] The ratio between the length of the support element and the length of the rod of the aerosol generating substrate is at least about 0.3, more preferably at least about 0.4, and even more preferably at least about 0.5. In a preferred embodiment, the ratio between the length of the support element and the length of the rod of the aerosol generating substrate is less than about 0.9, more preferably less than about 0.8, and even more preferably less than about 0.7.

[0138] In some embodiments, the ratio between the length of the support element and the length of the rod of the aerosol generating substrate is about 0.3 to about 0.9, preferably about 0.4 to about 0.9, and more preferably about 0.5 to about 0.9. In other embodiments, the ratio between the length of the support element and the length of the rod of the aerosol generating substrate is about 0.3 to about 0.8, preferably about 0.4 to about 0.8, and more preferably about 0.5 to about 0.8. In further embodiments, the ratio between the length of the support element and the length of the rod of the aerosol generating substrate is about 0.3 to about 0.7, preferably about 0.4 to about 0.7, and more preferably about 0.5 to about 0.7.

[0139] In a particularly preferred embodiment, the ratio between the length of the support element and the length of the rod of the aerosol generating substrate is about 0.66.

[0140] The ratio between the length of the support element and the total length of the aerosol-generating article substrate can be approximately 0.125 to approximately 0.375.

[0141] Preferably, the ratio between the length of the support element and the total length of the aerosol-generating article substrate is at least about 0.13, more preferably at least about 0.14, and even more preferably at least about 0.15. Preferably, the ratio between the length of the support element and the total length of the aerosol-generating article substrate is less than about 0.3, more preferably less than about 0.25, and even more preferably less than about 0.20.

[0142] In some embodiments, the ratio between the length of the support element and the total length of the aerosol-generating article substrate is preferably about 0.13 to about 0.3, more preferably about 0.14 to about 0.3, and even more preferably about 0.15 to about 0.3. In other embodiments, the ratio between the length of the support element and the total length of the aerosol-generating article substrate is preferably about 0.13 to about 0.25, more preferably about 0.14 to about 0.25, and even more preferably about 0.15 to about 0.25. In further embodiments, the ratio between the length of the support element and the total length of the aerosol-generating article substrate is preferably about 0.13 to about 0.2, more preferably about 0.14 to about 0.2, and even more preferably about 0.15 to about 0.2.

[0143] In a particularly preferred embodiment, the ratio between the length of the support element and the total length of the aerosol-generating article substrate is about 0.18.

[0144] In the aerosol-generating article according to the present invention, the support element preferably has an average radial hardness of at least about 80 percent, more preferably at least about 85 percent, and even more preferably at least about 90 percent. Therefore, the support element can provide the aerosol-generating article with a desired hardness level.

[0145] If desired, the radial hardness of the support elements of the aerosol-generating article according to the present invention may be further increased by surrounding the support elements with a rigid plug wrap, such as a plug wrap having a basis weight of at least about 80 grams / square meter (gsm), at least about 100 gsm, or at least about 110 gsm.

[0146] When inserting an aerosol generating article into an aerosol generator according to the present invention for heating the aerosol generating substrate, the user may need to apply some force to overcome the resistance of the aerosol generating article to the insertion of the aerosol generating substrate. This may damage one or both of the aerosol generating article and / or the aerosol generator. In addition, the application of force during insertion of the aerosol generating article into the aerosol generator may displace the aerosol generating substrate within the aerosol generating article. This may result in the heating element of the aerosol generator not being properly aligned with the susceptor element provided within the aerosol generating substrate, potentially leading to uneven and inefficient heating of the aerosol generating substrate of the aerosol generating article. The support element is advantageously configured to resist the downstream movement of the aerosol generating substrate during insertion of the article into the aerosol generator.

[0147] Preferably, the hollow tubular segment of the support element is adapted to generate an RTD of from approximately 0 millimeters of H2O (about 0 Pa) to approximately 20 millimeters of H2O (about 100 Pa), more preferably from approximately 0 millimeters of H2O (about 0 Pa) to approximately 10 millimeters of H2O (about 100 Pa). Thus, the support element preferably does not contribute to the overall RTD of the aerosol-generating article.

[0148] In some embodiments where the intermediate hollow section includes both a support element including a first hollow tube segment and an aerosol cooling element including a second hollow tubular segment, the inner diameter (D STS ) of the second hollow tubular segment is preferably larger than the inner diameter (D FTS ) of the first hollow tubular segment.

[0149] More specifically, the ratio between the inner diameter (D STS ) of the second hollow tubular segment and the inner diameter (D FTS ) of the first hollow tubular segment is preferably at least about 1.25. More preferably, the ratio between the inner diameter (D STS ) of the second hollow tubular segment and the inner diameter (D FTS ) of the first hollow tubular segment is preferably at least about 1.3. Even more preferably, the ratio between the inner diameter (D STS ) of the second hollow tubular segment and the inner diameter (D FTS ) of the first hollow tubular segment is preferably at least about 1.4. In particularly preferred embodiments, the ratio between the inner diameter (D STS ) of the second hollow tubular segment and the inner diameter (D FTS ) of the first hollow tubular segment is at least about 1.5, more preferably at least about 1.6.

[0150] The ratio between the inner diameter (D STS ) of the second hollow tubular segment and the inner diameter (D FTS ) of the first hollow tubular segment is preferably about 2.5 or less. More preferably, the inner diameter (D STS ) of the second hollow tubular segment and the inner diameter (DFTS The ratio between (D) and (D) is preferably about 2.25 or less. More preferably, the inner diameter (D) of the second hollow tubular segment is STS ) and the inner diameter (D) of the first hollow tubular segment FTS The ratio between ) and is preferably about 2 or less.

[0151] In some embodiments, the inner diameter (D) of the second hollow tubular segment STS ) and the inner diameter (D) of the first hollow tubular segment FTS The ratio between (D) and (D) is approximately 1.25 to approximately 2.5. Preferably, the inner diameter (D) of the second hollow tubular segment is STS ) and the inner diameter (D) of the first hollow tubular segment FTS The ratio between (D) and (D) is approximately 1.3 to approximately 2.5. More preferably, the inner diameter (D) of the second hollow tubular segment is STS ) and the inner diameter (D) of the first hollow tubular segment FTS The ratio between (D) and (D) is approximately 1.4 to approximately 2.5. In a particularly preferred embodiment, the inner diameter (D) of the second hollow tubular segment is approximately 1.4 to 2.5. STS ) and the inner diameter (D) of the first hollow tubular segment FTS The ratio between ) is approximately 1.5 to 2.5.

[0152] In other embodiments, the inner diameter (D) of the second hollow tubular segment STS ) and the inner diameter (D) of the first hollow tubular segment FTS The ratio between (D) and (D) is approximately 1.25 to approximately 2.25. Preferably, the inner diameter (D) of the second hollow tubular segment is STS ) and the inner diameter (D) of the first hollow tubular segment FTS The ratio between (D) and (D) is approximately 1.3 to approximately 2.25. More preferably, the inner diameter (D) of the second hollow tubular segment is STS ) and the inner diameter (D) of the first hollow tubular segment FTS The ratio between (D) and (D) is approximately 1.4 to approximately 2.25. In a particularly preferred embodiment, the inner diameter (D) of the second hollow tubular segment is approximately 1.4 to approximately 2.25. STS ) and the inner diameter (D) of the first hollow tubular segment FTS The ratio between ) is approximately 1.5 to 2.25.

[0153] In a further embodiment, the inner diameter (D) of the second hollow tubular segment STS ) and the inner diameter (D) of the first hollow tubular segment FTS The ratio between (D) and (D) is approximately 1.25 to approximately 2. Preferably, the inner diameter (D) of the second hollow tubular segment is STS ) and the inner diameter (D) of the first hollow tubular segment FTS The ratio between (D) and (D) is about 1.3 to about 2. More preferably, the inner diameter (D) of the second hollow tubular segment is STS ) and the inner diameter (D) of the first hollow tubular segment FTS The ratio between (D) and (D) is about 1.4 to about 2. In a particularly preferred embodiment, the inner diameter (D) of the second hollow tubular segment is about 1.4 to about 2. STS ) and the inner diameter (D) of the first hollow tubular segment FTS The ratio between ) is approximately 1.5 to 2.

[0154] In these embodiments, the article further comprises an elongated susceptor element arranged longitudinally within the aerosol generating substrate, as described below, the inner diameter (D) of the first hollow tubular segment. FTS The ratio between the inner diameter (D) of the first hollow tubular segment and the width of the susceptor element is preferably at least about 0.2. More preferably, the ratio between the inner diameter (D) of the first hollow tubular segment is preferably at least about 0.2. FTS The ratio between the inner diameter (D) of the first hollow tubular segment and the width of the susceptor element is at least about 0.3. More preferably, the ratio between the inner diameter (D) of the first hollow tubular segment is at least about 0.3. FTS The ratio between the width of the susceptor element and the width of the susceptor element is at least approximately 0.4.

[0155] In addition, or alternatively, the inner diameter (D) of the second hollow tubular segment. STS The ratio between the inner diameter (D) of the second hollow tubular segment and the width of the susceptor element is preferably at least about 0.2. More preferably, the ratio between the inner diameter (D) of the second hollow tubular segment is preferably at least about 0.2. STS The ratio between the inner diameter (D) of the second hollow tubular segment and the width of the susceptor element is at least about 0.5. More preferably, the ratio between the inner diameter (D) of the second hollow tubular segment is at least about 0.5. STS The ratio between the width of the susceptor element and the width of the susceptor element is at least approximately 0.8.

[0156] Preferably, the ratio of the volume of the cavity in the first hollow tubular segment to the volume of the cavity in the second hollow tubular segment is at least about 0.1. More preferably, the ratio of the volume of the cavity in the first hollow tubular segment to the volume of the cavity in the second hollow tubular segment is at least about 0.2. Even more preferably, the ratio of the volume of the cavity in the first hollow tubular segment to the volume of the cavity in the second hollow tubular segment is at least about 0.3.

[0157] Preferably, the ratio of the volume of the cavity in the first hollow tubular segment to the volume of the cavity in the second hollow tubular segment is about 0.9 or less. More preferably, the ratio of the volume of the cavity in the first hollow tubular segment to the volume of the cavity in the second hollow tubular segment is about 0.7 or less. Even more preferably, the ratio of the volume of the cavity in the first hollow tubular segment to the volume of the cavity in the second hollow tubular segment is about 0.5 or less.

[0158] As described above, the aerosol generating article of the present invention comprises a rod of an aerosol generating substrate. The aerosol generating substrate may be a solid aerosol generating substrate.

[0159] In a particular preferred embodiment, the aerosol-generating substrate comprises homogenized plant material, preferably homogenized tobacco material.

[0160] As used herein, the term “homogenized plant material” encompasses any plant material formed by the aggregation of plant particles. For example, a sheet or web of homogenized tobacco material for the aerosol-generating substrate of the present invention may be formed by aggregating plant material and, optionally, tobacco material particles obtained by grinding, crushing, or pulverizing one or more of tobacco leaf blades and tobacco leaf stems. The homogenized plant material may be produced by casting, extrusion, papermaking processes, or any other suitable process known in the art.

[0161] Homogenized plant material can be provided in any preferred form. For example, homogenized plant material may be in the form of one or more sheets. As used herein in relation to the present invention, the term “sheet” refers to a thin layer element having a width and length considerably greater than its thickness.

[0162] Alternatively, or additionally, the homogenized plant material may be in the form of multiple pellets or granules.

[0163] Alternatively, or additionally, the homogenized plant material may be in the form of multiple strands, strips, or fragments. As used herein, the term “strand” refers to an elongated element of the material having a length substantially greater than its width and thickness. The term “strand” is considered to encompass strips, fragments, and any other homogenized plant material having a similar form. Strands of homogenized plant material may be formed from a sheet of homogenized plant material, for example, by cutting or shredding, or by other means, such as by extrusion.

[0164] In some embodiments, strands may be formed in situ within the aerosol-generating substrate as a result of splitting or cracking of a sheet of homogenized plant material during the formation of the aerosol-generating substrate, for example, as a result of crimping. The strands of homogenized plant material within the aerosol-generating substrate may be separated from each other. Alternatively, each strand of homogenized plant material within the aerosol-generating substrate may be at least partially connected to adjacent strands along the length of the strand. For example, adjacent strands may be connected by one or more fibers. This may occur, for example, when strands are formed as a result of splitting of a sheet of homogenized plant material during the manufacture of the aerosol-generating substrate as described above.

[0165] The aerosol generating substrate is preferably in the form of one or more sheets of homogenized plant material. In various embodiments of the present invention, one or more sheets of homogenized plant material may be produced by a casting process. In various embodiments of the present invention, one or more sheets of homogenized plant material may be produced by a papermaking process. Each of the one or more sheets described herein may individually have a thickness of 100 to 600 micrometers, preferably 150 to 300 micrometers, and most preferably 200 to 250 micrometers. Individual thicknesses refer to the thickness of individual sheets, and combined thickness refers to the total thickness of all sheets constituting the aerosol generating substrate. For example, if the aerosol generating substrate is formed from two individual sheets, the combined thickness is the thickness of the two individual sheets, or the sum of the measured thicknesses of the two sheets, and the two sheets are stacked within the aerosol generating substrate.

[0166] Each of the sheets described herein is individually approximately 100 g / m² 2 ~about 300g / m 2 It may have a basis weight.

[0167] Each of the sheets described herein contains approximately 0.3 g / cm² of material. 3 ~Approx. 1.3g / cm 3 It may have a density of approximately 0.7 g / cm³. 3 ~Approx. 1.0g / cm 3 It is preferable that it has a density of [value missing].

[0168] In embodiments of the present invention, the aerosol generating substrate comprises one or more sheets of homogenized plant material, the sheets are preferably in the form of an aggregate of one or more sheets. As used herein, the term “aggregate” means that the sheets of homogenized plant material are spiraled substantially transversely to the cylindrical axis of a plug or rod, folded, or otherwise compressed or shrunk.

[0169] One or more sheets of homogenized plant material can be assembled transversely to their longitudinal axis and surrounded by a wrapper to form a continuous rod or plug.

[0170] One or more sheets of homogenized plant material may be advantageously crimped or similarly treated. As used herein, the term “crimped” means a sheet having multiple substantially parallel ridges or undulations. In addition to or otherwise than crimping, one or more sheets of homogenized plant material may be embossed, debossed, perforated, or otherwise deformed to provide texture on one or both sides of the sheet.

[0171] Preferably, each sheet of homogenized plant material can be crimped to have multiple ridges or undulations substantially parallel to the cylindrical axis of the plug. This process advantageously facilitates the assembly of the crimped sheets of homogenized plant material to form the plug. Preferably, one or more sheets of homogenized plant material can be assembled. Naturally, the crimped sheets of homogenized plant material may, by other means or additionally, have multiple substantially parallel ridges or undulations that form acute or obtuse angles with respect to the cylindrical axis of the plug. The sheets may be crimped to such an extent that the integrity of the sheet is interrupted at the multiple parallel ridges or undulations, causing separation of the material and resulting in the formation of fragments, strands, or shards of homogenized plant material.

[0172] Alternatively, one or more sheets of homogenized plant material may be cut into strands, as mentioned above. In such embodiments, the aerosol-generating substrate comprises several strands of homogenized plant material. The strands may be used to form a plug. Typically, the width of such strands is about 5 millimeters, or about 4 millimeters, or about 3 millimeters, or less than 2 millimeters. The length of the strands may be longer than about 5 millimeters, or between about 5 millimeters and about 15 millimeters, or between about 8 millimeters and about 12 millimeters, or about 12 millimeters. It is preferable that the strands are substantially the same length as each other. The length of the strands may be determined by a manufacturing process, thereby cutting the rods into shorter plugs, and the length of the strands corresponds to the length of the plugs. The strands are fragile and can break, especially during transport. In such cases, the length of some strands may be shorter than the length of the plugs.

[0173] It is preferable that the strands are aligned with the longitudinal axis and extend substantially along the length of the aerosol-generating substrate. Therefore, it is preferable that the strands are aligned substantially parallel to one another.

[0174] The homogenized plant material may contain up to about 95 weight percent of plant particles on a dry weight basis. Preferably, the homogenized plant material contains up to about 90 weight percent of plant particles on a dry weight basis, more preferably about 80 weight percent of plant particles, more preferably about 70 weight percent of plant particles, more preferably about 60 weight percent of plant particles, and more preferably about 50 weight percent of plant particles.

[0175] For example, homogenized plant material may contain, on a dry weight basis, approximately 2.5 to 95 percent by weight of plant particles, or approximately 5 to 90 percent by weight of plant particles, or approximately 10 to 80 percent by weight of plant particles, or approximately 15 to 70 percent by weight of plant particles, or approximately 20 to 60 percent by weight of plant particles, or approximately 30 to 50 percent by weight of plant particles.

[0176] In certain embodiments of the present invention, the homogenized plant material is a homogenized tobacco material containing tobacco particles. A sheet of homogenized tobacco material used in such embodiments of the present invention may have a tobacco content of at least about 40 weight percent on a dry weight basis, more preferably at at least about 50 weight percent on a dry weight basis, more preferably at at least about 70 weight percent on a dry weight basis, and most preferably at at least about 90 weight percent on a dry weight basis.

[0177] In relation to the present invention, the term “tobacco particles” refers to particles of any plant material of the Nicotiana species. The term “tobacco particles” encompasses crushed or powdered tobacco leaf lamina, crushed or powdered tobacco leaf stems, tobacco dust, tobacco fine powder, and other particulate tobacco by-products formed during the processing, handling, and shipping of tobacco. In preferred embodiments, tobacco particles are substantially all derived from tobacco leaf lamina. In contrast, isolated nicotine and nicotine salts, although compounds derived from tobacco, are not considered tobacco particles for the purposes of the present invention and are not included in the proportion of particulate plant material.

[0178] Tobacco particles can be prepared from one or more varieties of tobacco plants. Any type of tobacco can be used in the blend. Examples of types of tobacco materials that can be used include, but are not limited to, sun-dried tobacco, heat-dried tobacco, Burley tobacco, Maryland tobacco, Oriental tobacco, Virginia tobacco, and other specialty tobaccos.

[0179] Heat drying is a tobacco drying method particularly used for Virginia tobacco. During the heat drying process, heated air circulates through the densely packed tobacco. In the first stage, the tobacco leaves turn yellow and wither. In the second stage, the leaf laminas dry completely. In the third stage, the leaf stems dry completely.

[0180] Burley tobacco plays an important role in many tobacco blends. Burley tobacco possesses a distinctive flavor and aroma, and has the ability to absorb a large amount of casing.

[0181] Oriental tobacco is a type of tobacco with small leaves and high aromatic quality. However, Oriental tobacco has a milder flavor than, for example, Burley tobacco. Therefore, Oriental tobacco is generally used in relatively small proportions in tobacco blends.

[0182] Kasturi, Madura, and Jatim are usable subtypes of sun-dried tobacco. It is preferable to use Kasturi tobacco and heat-dried tobacco in the blend to produce tobacco particles. Therefore, tobacco particles in particulate plant material may include a blend of Kasturi tobacco and heat-dried tobacco.

[0183] Tobacco particles may have a nicotine content of at least about 2.5 weight percent based on dry weight. More preferably, tobacco particles may have a nicotine content of at least about 3 weight percent based on dry weight, even more preferably at least about 3.2 weight percent, even more preferably at least about 3.5 weight percent, and most preferably at least about 4 weight percent.

[0184] In certain other embodiments of the present invention, the homogenized plant material includes tobacco particles combined with non-tobacco plant-flavored particles. Preferably, the non-tobacco plant-flavored particles are selected from one or more of ginger particles, rosemary particles, eucalyptus particles, clove particles, and star anise particles. Preferably, in such embodiments, the homogenized plant material contains at least about 2.5 weight percent of non-tobacco plant-flavored particles on a dry weight basis, with the remaining plant particles being tobacco particles. Preferably, the homogenized plant material contains at least about 4 weight percent of non-tobacco plant-flavored particles on a dry weight basis, more preferably at least about 6 weight percent of non-tobacco plant-flavored particles, more preferably at least about 8 weight percent of non-tobacco plant-flavored particles, and more preferably at least about 10 weight percent of non-tobacco plant-flavored particles. Preferably, the homogenized plant material contains up to about 20 weight percent of non-tobacco plant-flavored particles, more preferably up to about 18 weight percent of non-tobacco plant-flavored particles, and more preferably up to about 16 weight percent of non-tobacco plant-flavored particles.

[0185] The weight ratio of non-tobacco plant-flavored particles to tobacco particles in the particulate plant material forming the homogenized plant material may vary depending on the desired flavor characteristics and composition of the aerosol generated from the aerosol-generating substrate during use. Preferably, the homogenized plant material contains, on a dry weight basis, at least 1:30 weight ratio of non-tobacco plant-flavored particles to tobacco particles, more preferably at least 1:20 weight ratio of non-tobacco plant-flavored particles to tobacco particles, more preferably at least 1:10 weight ratio of non-tobacco plant-flavored particles to tobacco particles, and most preferably at least 1:5 weight ratio of non-tobacco plant-flavored particles to tobacco particles.

[0186] As an alternative to, or in addition to, the homogenized plant material of the aerosol-generating substrate according to the present invention, the homogenized plant material may also contain cannabis particles. The term "cannabis particles" refers to particles of cannabis plants such as Cannabis sativa, Cannabis indica, and Cannabis ruderalis.

[0187] The homogenized plant material preferably contains 95% by weight or less of particulate plant material on a dry weight basis. Thus, the particulate plant material is typically combined with one or more other components to form the homogenized plant material.

[0188] Homogenized plant material may further contain a binder for altering the mechanical properties of particulate plant material, where the binder is included in the homogenized plant material during production as described herein. Suitable exogenous binders known to those skilled in the art include, but are not limited to, gums such as guar gum, xanthan gum, gum arabic, and locust bean gum; cellulose binders such as hydroxypropyl cellulose, carboxymethyl cellulose, hydroxyethyl cellulose, methyl cellulose, and ethyl cellulose; polysaccharides such as starch, organic acids such as alginic acid, conjugated base salts of organic acids such as sodium alginate, agar, and pectin, and combinations thereof. The binder preferably contains guar gum.

[0189] The binder may be present in an amount of about 1% to about 10% by weight, preferably about 2% to about 5% by weight, based on the dry weight of the homogenized plant material.

[0190] Alternatively, or additionally, the homogenized plant material may further contain one or more lipids to facilitate the diffusion of volatile components (e.g., aerosol-forming agents, gingerol, and nicotine), wherein the lipids are included in the homogenized plant material during the manufacturing process described herein. Suitable lipids for inclusion in the homogenized plant material include, but are not limited to, medium-chain triglycerides, cocoa butter, palm oil, kernel oil, mango oil, shea butter, soybean oil, cottonseed oil, coconut oil, hydrogenated coconut oil, candelilla wax, carnauba wax, shellac, sunflower wax, sunflower oil, rice bran, and RevelA, as well as combinations thereof.

[0191] Alternatively, or additionally, the homogenized plant material may further contain a pH adjuster.

[0192] Alternatively, or additionally, the homogenized plant material may further contain fibers to alter the mechanical properties of the homogenized plant material, wherein the fibers are included in the homogenized plant material during the manufacturing process described herein. Suitable exogenous fibers for inclusion in the homogenized plant material are known in the art and include, but are not limited to, cellulose fibers, soft wood fibers, hard wood fibers, jute fibers, and combinations thereof, including fibers formed from non-tobacco and non-ginger materials. Exogenous fibers derived from tobacco and / or ginger may also be added. Any fibers added to the homogenized plant material are not considered to form part of the “particulate plant material” as defined above. Before inclusion in the homogenized plant material, the fibers may be treated by suitable processes known in the art, including, but not limited to, mechanical pulping, purification, chemical pulping, bleaching, sulfate pulping, and combinations thereof. Typically, the fibers have a length greater than their width.

[0193] Preferred fibers are typically greater than 400 micrometers and have a length of 4 millimeters or less, preferably in the range of 0.7 millimeters to 4 millimeters. The fibers are preferably present in an amount of about 2% to about 15% by weight, most preferably about 4% by weight, based on the dry weight of the substrate.

[0194] Alternatively, or additionally, the homogenized plant material may further contain one or more aerosol-forming bodies. Upon volatilization, the aerosol-forming bodies can carry other vaporized compounds released from the aerosol-generating substrate upon heating, such as nicotine and flavoring agents in the aerosol. Suitable aerosol-forming bodies for inclusion in the homogenized plant material are known in the art and include, but are not limited to, polyhydric alcohols (such as triethylene glycol, propylene glycol, 1,3-butanediol, and glycerol), esters of polyhydric alcohols (glycerol mono-, di-, or triacetate), and aliphatic esters of mono-, di-, or polycarboxylic acids (such as dodecanedioic acid and dimethyl tetradecanedioic acid).

[0195] Homogenized plant material may have an aerosol-forming content of approximately 5% to 30% by dry weight, such as approximately 10% to 25% by dry weight, or approximately 15% to 20% by dry weight.

[0196] For example, when intended for use in an aerosol generating article for an electrically operated aerosol generating system having a substrate that has a heating element, it is preferable that the aerosol-forming material content be about 5% to about 30% by weight on a dry weight basis. When intended for use in an aerosol generating article for an electrically operated aerosol generating system having a substrate that has a heating element, the aerosol-forming material is preferably glycerol.

[0197] In another embodiment, the homogenized plant material may have an aerosol-forming content of about 1% to about 5% by weight on a dry weight basis. For example, if the substrate is intended for use in an aerosol-generating article in which the aerosol-forming material is kept in a storage compartment separated from the substrate, the substrate may have an aerosol-forming content greater than 1% and less than about 5%. In such embodiments, the aerosol-forming material volatilizes upon heating, and the flow of the aerosol-forming material comes into contact with the aerosol-generating substrate to infuse flavor from the aerosol-generating substrate into the aerosol.

[0198] In another embodiment, the homogenized plant material may have an aerosol-forming content of about 30 to about 45 weight percent. This relatively high level of aerosol-forming is particularly suitable for aerosol-generating substrates intended to be heated at temperatures below 275 degrees Celsius. In such embodiments, the homogenized plant material preferably further comprises about 2 to about 10 weight percent of cellulose ether and about 5 to about 50 weight percent of additional cellulose on a dry weight basis. The use of a combination of cellulose ether and additional cellulose has been found to result in particularly effective aerosol delivery when used in aerosol-generating substrates having an aerosol-forming content of 30 to 45 weight percent.

[0199] Suitable cellulose ethers include, but are not limited to, methylcellulose, hydroxypropylmethylcellulose, ethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, ethylhydroxyethylcellulose, and carboxymethylcellulose (CMC). In a particularly preferred embodiment, the cellulose ether is carboxymethylcellulose.

[0200] As used herein, the term “additional cellulose” encompasses any cellulose material incorporated into the homogenized plant material, which does not originate from the non-tobacco plant particles or tobacco particles provided to the homogenized plant material. Thus, additional cellulose is incorporated into the homogenized plant material as an individual and distinct source of cellulose to any cellulose essentially provided within the non-tobacco plant particles or tobacco particles, in addition to the non-tobacco plant material or tobacco material. The additional cellulose typically originates from a plant different from the non-tobacco plant particles or tobacco particles. Preferably, the additional cellulose is in the form of an inert cellulose material, which is sensorily inert and therefore does not substantially affect the functional properties of the aerosol generated from the aerosol-generating substrate. For example, the additional cellulose is preferably a tasteless and odorless material.

[0201] The additional cellulose may include cellulose powder, cellulose fibers, or a combination thereof.

[0202] The aerosol-forming material can act as a wetting agent in the aerosol-generating substrate.

[0203] The wrapper surrounding the rod of homogenized plant material may be a paper wrapper or a non-paper wrapper. Suitable paper wrappers for use in specific embodiments of the present invention are known in the art and include, but are not limited to, cigarette papers and filter plug wrappers. Suitable non-paper wrappers for use in specific embodiments of the present invention are known in the art and include, but are not limited to, sheets of homogenized tobacco material. In certain preferred embodiments, the wrapper may be formed from a laminated material comprising multiple layers. Preferably, the wrapper is formed from an aluminum co-laminate sheet. The use of an aluminum co-laminate sheet advantageously prevents combustion of the aerosol-generating substrate when the aerosol-generating substrate is to be ignited rather than heated in the intended manner.

[0204] In other preferred embodiments of the present invention, the aerosol generating substrate comprises a gel composition containing an alkaloid compound, or a cannabinoid compound, or both an alkaloid compound and a cannabinoid compound. In particularly preferred embodiments, the aerosol generating substrate comprises a gel composition containing nicotine.

[0205] Preferably, the gel composition comprises an alkaloid compound, or a cannabinoid compound, or both an alkaloid compound and a cannabinoid compound, an aerosol-forming body, and at least one gelling agent. Preferably, at least one gelling agent forms a solid medium, glycerol is dispersed in the solid medium, and the alkaloid or cannabinoid is dispersed in the glycerol. The gel composition is preferably a stable gel phase.

[0206] Advantageously, a nicotine-containing stable gel composition provides a predictable compositional form during storage or during the transition from manufacture to consumer. The nicotine-containing stable gel composition substantially maintains its shape. The nicotine-containing stable gel composition substantially does not release the liquid phase during storage or during the transition from manufacture to consumer. The nicotine-containing stable gel composition may offer a simple consumable design. This consumable may not need to be designed to contain a liquid, and therefore a wider range of materials and container structures may be considered.

[0207] The gel compositions described herein may be combined with an aerosol generator to deliver nicotine aerosol to the lungs at inhalation rates or airflow rates within those of conventional smoking methods. The aerosol generator can continuously heat the gel composition. The consumer can take multiple inhalations or "smokes," each delivering an amount of nicotine aerosol. When heated, the gel composition can deliver a high nicotine / total particulate matter (TPM) aerosol to the consumer, preferably in a continuous manner.

[0208] The terms "stable gel phase" or "stable gel" refer to a gel that substantially maintains its shape and mass when exposed to various environmental conditions. A stable gel is substantially unable to release or absorb water (sweat) when exposed to standard temperature and pressure while the relative humidity is varied from approximately 10 percent to approximately 60 percent. For example, a stable gel can substantially maintain its shape and mass when exposed to standard temperature and pressure while the relative humidity is varied from approximately 10 percent to approximately 60 percent.

[0209] 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.

[0210] The term “alkaloid compound” means any one or more classes of naturally occurring organic compounds that contain one or more basic nitrogen atoms. Generally, alkaloids contain at least one nitrogen atom in an amine-type structure. This nitrogen atom or another nitrogen atom in the molecule of an alkaloid compound can be active as a base in acid-base reactions. Most alkaloid compounds have one or more of their nitrogen atoms as part of a cyclic system, such as a heterocycle. In nature, alkaloid compounds are found mainly in plants, and are particularly common in flowering plants of certain families. However, some alkaloid compounds are found in animal species and fungi. In this disclosure, the term “alkaloid compound” refers to both naturally occurring alkaloid compounds and synthetically produced alkaloid compounds.

[0211] The gel composition preferably contains an alkaloid compound selected from the group consisting of nicotine, anatabine, and combinations thereof.

[0212] Preferably, the gel composition contains nicotine.

[0213] The term "nicotine" refers to nicotine and nicotine derivatives (e.g., free base nicotine, nicotine salts, and similar substances).

[0214] The term “cannabinoid compound” means any one type of naturally occurring compound found in some cannabis plants, including Cannabis sativa, Cannabis indica, and Cannabis ruderalis. Cannabinoid compounds are particularly concentrated in female flower heads. Naturally occurring cannabinoid compounds in cannabis plants include cannabidiol (CBD) and tetrahydrocannabinol (THC). In this disclosure, the term “cannabinoid compound” is used to describe both naturally occurring and synthetically produced cannabinoid compounds.

[0215] The gel may contain cannabinoid compounds 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), cannabiersoin (CBE), cannabicitran (CBT), and combinations thereof.

[0216] The gel composition may preferably contain a cannabinoid compound selected from the group consisting of cannabidiol (CBD), THC (tetrahydrocannabinol), and combinations thereof.

[0217] The gel preferably contains cannabidiol (CBD).

[0218] The gel composition may contain nicotine and cannabidiol (CBD).

[0219] The gel composition may contain nicotine, cannabidiol (CBD), and THC (tetrahydrocannabinol).

[0220] The gel composition preferably contains about 0.5% to about 10% by weight of an alkaloid compound, or about 0.5% to about 10% by weight of a cannabinoid compound, or both alkaloid and cannabinoid compounds in a total amount of about 0.5% to about 10% by weight. The gel composition may contain about 0.5% to about 5% by weight of an alkaloid compound, or about 0.5% to about 5% by weight of a cannabinoid compound, or both alkaloid and cannabinoid compounds in a total amount of about 0.5% to about 5% by weight. The gel composition preferably contains about 1% to about 3% by weight of an alkaloid compound, or about 1% to about 3% by weight of a cannabinoid compound, or both alkaloid and cannabinoid compounds in a total amount of about 1% to about 3% by weight. The gel composition may preferably contain about 1.5% to about 2.5% by weight of an alkaloid compound, or about 1.5% to about 2.5% by weight of a cannabinoid compound, or both alkaloid and cannabinoid compounds in a total amount of about 1.5% to about 2.5% by weight. The gel composition may preferably contain about 2% by weight of an alkaloid compound, or about 2% by weight of a cannabinoid compound, or both alkaloid and cannabinoid compounds in a total amount of about 2% by weight. The alkaloid compound component of the gel formulation may be the most volatile component of the gel formulation. In some embodiments, water may be the most volatile component of the gel formulation, and the alkaloid compound component of the gel formulation may be the second most volatile component of the gel formulation. The cannabinoid compound component of the gel formulation may be the most volatile component of the gel formulation. In some embodiments, water may be the most volatile component of the gel formulation, and the alkaloid compound component of the gel formulation may be the second most volatile component of the gel formulation.

[0221] Preferably, nicotine is included in the gel composition. Nicotine may be added to the composition in free base form or salt form. The gel composition contains about 0.5% to about 10% by weight nicotine, or about 0.5% to about 5% by weight nicotine. Preferably, the gel composition contains about 1% to about 3% by weight nicotine, or about 1.5% to about 2.5% by weight nicotine, or about 2% by weight nicotine. The nicotine component of the gel formulation may be the most volatile component of the gel formulation. In some embodiments, water may be the most volatile component of the gel formulation, and the nicotine component of the gel formulation may be the second most volatile component of the gel formulation.

[0222] The gel composition preferably includes an aerosol-forming agent. Ideally, the aerosol-forming agent is substantially resistant to thermal degradation at the operating temperature of the associated aerosol generator. Suitable aerosol-forming agents include, but are not limited to, polyhydric alcohols (such as triethylene glycol, 1,3-butanediol, and glycerin), esters of polyhydric alcohols (such as glycerol monoacetate, diacetate, or triacetate), and aliphatic esters of monocarboxylic acids, dicarboxylic acids, or polycarboxylic acids (such as dimethyl dodecanediol and dimethyl tetradecanediol). The polyhydric alcohol or a 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-forming agent is preferably glycerol.

[0223] The gel composition contains the majority of the aerosol-forming material. The gel composition may contain a mixture of water and the aerosol-forming material, the aerosol-forming material forming the majority (by weight) of the gel composition. The aerosol-forming material may form at least about 50 weight percent of the gel composition. The aerosol-forming material may form at least about 60 weight percent, or at least about 65 weight percent, or at least about 70 weight percent of the gel composition. The aerosol-forming material may form about 70 to about 80 weight percent of the gel composition. The aerosol-forming material may form about 70 to about 75 weight percent of the gel composition.

[0224] The gel composition may consist mostly of glycerol. The gel composition may consist of a mixture of water and glycerol, with glycerol forming the majority (by weight) of the gel composition. Glycerol may form at least about 50 weight percent of the gel composition. Glycerol may form at least about 60 weight percent, or at least about 65 weight percent, or at least about 70 weight percent of the gel composition. Glycerol may form about 70 to about 80 weight percent of the gel composition. Glycerol may form about 70 to about 75 weight percent of the gel composition.

[0225] The gel composition preferably contains at least one gelling agent. The gel composition preferably contains gelling agents in a total amount ranging from about 0.4% to about 10% by weight. More preferably, the composition contains gelling agents in a range of about 0.5% to about 8% by weight. More preferably, the composition contains gelling agents in a range of about 1% to about 6% by weight. More preferably, the composition contains gelling agents in a range of about 2% to about 4% by weight. More preferably, the composition contains gelling agents in a range of about 2% to about 3% by weight.

[0226] The term "gelling agent" refers to a compound that, when added homogeneously to a mixture of 50% water and 50% glycerol in an amount of approximately 0.3% by weight, forms a solid culture medium or supporting matrix, leading to the formation of a gel. Examples of gelling agents, though not limited to them, include hydrogen-linked gelling agents and ion-linked gelling agents.

[0227] The gelling agent may contain one or more biopolymers. The biopolymers may be formed from polysaccharides.

[0228] Examples of biopolymers include gellan gum (natural gellan gum, low-acyl gellan gum, high-acyl gellan gum, and low-acyl gellan gum are preferred), xanthan gum, alginate (alginic acid), agar, and guar gum. It is preferable that the composition contains xanthan gum. The composition may contain two biopolymers. The composition may contain three biopolymers. The composition may contain two biopolymers in substantially equal weights. The composition may contain three biopolymers in substantially equal weights.

[0229] Preferably, the gel composition contains at least about 0.2 weight percent of a hydrogen-bonding crosslinking gelling agent. Alternatively or additionally, the gel composition preferably contains at least about 0.2 weight percent of an ion-crosslinking gelling agent. Most preferably, the gel composition contains at least about 0.2 weight percent of a hydrogen-bonding crosslinking gelling agent and at least about 0.2 weight percent of an ion-crosslinking gelling agent. The gel composition may contain about 0.5 to about 3 weight percent of a hydrogen-bonding crosslinking gelling agent and about 0.5 to about 3 weight percent of an ion-crosslinking gelling agent, or about 1 to about 2 weight percent of a hydrogen-bonding crosslinking gelling agent and about 1 to about 2 weight percent of an ion-crosslinking gelling agent. The hydrogen-bonding crosslinking gelling agent and the ion-crosslinking gelling agent may be present in substantially equal amounts in the gel composition.

[0230] The term "hydrogen bond crosslinking gelling agent" refers to a gelling agent that forms non-covalent or physical crosslinks via hydrogen bonds. Hydrogen bonds are not covalent bonds to hydrogen atoms, but rather a type of electrostatic dipole-dipole attraction between molecules. This results from the attraction between a hydrogen atom covalently bonded to an extremely electronegative atom, such as N, O, or F atoms, and another extremely electronegative atom.

[0231] The hydrogen bonding crosslinking gelling agent may contain one or more of galactomannan, gelatin, agarose, konjac gum, or agar. It is preferable that the hydrogen bonding crosslinking gelling agent contains agar.

[0232] The gel composition preferably contains a hydrogen bonding crosslinking gelling agent in an amount ranging from about 0.3% to about 5% by weight. Preferably, the composition contains a hydrogen bonding crosslinking gelling agent in an amount ranging from about 0.5% to about 3% by weight. Preferably, the composition contains a hydrogen bonding crosslinking gelling agent in an amount ranging from about 1% to about 2% by weight.

[0233] The gel composition may contain galactomannan in an amount ranging from about 0.2% to about 5% by weight. Preferably, the galactomannan may be in an amount ranging from about 0.5% to about 3% by weight. Preferably, the galactomannan may be in an amount ranging from about 0.5% to about 2% by weight. Preferably, the galactomannan may be in an amount ranging from about 1% to about 2% by weight.

[0234] The gel composition may contain gelatin in an amount ranging from about 0.2% to about 5% by weight. Preferably, the amount of gelatin may be in the range of about 0.5% to about 3% by weight. Preferably, the amount of gelatin may be in the range of about 0.5% to about 2% by weight. Preferably, the amount of gelatin may be in the range of about 1% to about 2% by weight.

[0235] The gel composition may contain agarose in an amount ranging from about 0.2% to about 5% by weight. Preferably, the agarose may be in an amount ranging from about 0.5% to about 3% by weight. Preferably, the agarose may be in an amount ranging from about 0.5% to about 2% by weight. Preferably, the agarose may be in an amount ranging from about 1% to about 2% by weight.

[0236] The gel composition may contain konjac gum in an amount ranging from about 0.2% to about 5% by weight. Preferably, the amount of konjac gum may be in the range of about 0.5% to about 3% by weight. Preferably, the amount of konjac gum may be in the range of about 0.5% to about 2% by weight. Preferably, the amount of konjac gum may be in the range of about 1% to about 2% by weight.

[0237] The gel composition may contain agar in an amount ranging from about 0.2% to about 5% by weight. Preferably, the agar may be in an amount ranging from about 0.5% to about 3% by weight. Preferably, the agar may be in an amount ranging from about 0.5% to about 2% by weight. Preferably, the agar may be in an amount ranging from about 1% to about 2% by weight.

[0238] The term "ionic crosslinking gelling agent" refers to a gelling agent that forms non-covalent or physical crosslinks via ionic bonding. Ionic crosslinking involves the association of polymer chains through non-covalent interactions. A crosslinking network is formed when polyvalent molecules with opposite charges are electrostatically attracted to each other, creating a crosslinked polymer network.

[0239] The ion-crosslinking gelling agent may include low-acylgellan, pectin, kappa-carrageenan, iota-carrageenan, or alginate. It is preferable that the ion-crosslinking gelling agent may include low-acylgellan.

[0240] The gel composition may contain an ion-crosslinking gelling agent in an amount ranging from about 0.3% to about 5% by weight. Preferably, the composition contains an ion-crosslinking gelling agent in an amount ranging from about 0.5% to about 3% by weight. Preferably, the composition contains an ion-crosslinking gelling agent in an amount ranging from about 1% to about 2% by weight.

[0241] The gel composition may contain low acylgelane in an amount ranging from about 0.2% to about 5% by weight. Preferably, the low acylgelane may be in an amount ranging from about 0.5% to about 3% by weight. Preferably, the low acylgelane may be in an amount ranging from about 0.5% to about 2% by weight. Preferably, the low acylgelane may be in an amount ranging from about 1% to about 2% by weight.

[0242] The gel composition may contain pectin in an amount ranging from about 0.2% to about 5% by weight. Preferably, the pectin may be in the range of about 0.5% to about 3% by weight. Preferably, the pectin may be in the range of about 0.5% to about 2% by weight. Preferably, the pectin may be in the range of about 1% to about 2% by weight.

[0243] The gel composition may contain kappacarrageenan in an amount ranging from about 0.2% to about 5% by weight. Preferably, the amount of kappacarrageenan may be in the range of about 0.5% to about 3% by weight. Preferably, the amount of kappacarrageenan may be in the range of about 0.5% to about 2% by weight. Preferably, the amount of kappacarrageenan may be in the range of about 1% to about 2% by weight.

[0244] The gel composition may contain iotacarrageenan in an amount ranging from about 0.2% to about 5% by weight. Preferably, the amount of iotacarrageenan may be in the range of about 0.5% to about 3% by weight. Preferably, the amount of iotacarrageenan may be in the range of about 0.5% to about 2% by weight. Preferably, the amount of iotacarrageenan may be in the range of about 1% to about 2% by weight.

[0245] The gel composition may contain alginate in an amount ranging from about 0.2% to about 5% by weight. Preferably, the alginate may be in the range of about 0.5% to about 3% by weight. Preferably, the alginate may be in the range of about 0.5% to about 2% by weight. Preferably, the alginate may be in the range of about 1% to about 2% by weight.

[0246] The gel composition may contain a hydrogen bonding crosslinking gelling agent and an ion crosslinking gelling agent in a ratio of approximately 3:1 to approximately 1:3. Preferably, the gel composition may contain a hydrogen bonding crosslinking gelling agent and an ion crosslinking gelling agent in a ratio of approximately 2:1 to approximately 1:2. Preferably, the gel composition may contain a hydrogen bonding crosslinking gelling agent and an ion crosslinking gelling agent in a ratio of approximately 1:1.

[0247] The gel composition may further contain a thickening agent. Surprisingly, thickening agents combined with hydrogen-bonding crosslinking gelling agents appear to support the solid medium and maintain the gel composition even when it contains high levels of glycerol.

[0248] The term "thickening agent" refers to a compound that, when uniformly added in an amount of 0.3 weight percent to a mixture of 50 weight percent water / 50 weight percent glycerin at 25°C, increases viscosity without causing gel formation, and causes the mixture to remain in a fluid state or stay fluid. Preferably, the thickening agent, when uniformly added in an amount of 0.3 weight percent to a mixture of 50 weight percent water / 50 weight percent glycerin at 25°C, increases viscosity by 0.1 s -1This refers to a compound that, at a shear rate of 0.1°C, increases the viscosity to at least 50 cPs, preferably at least 200 cPs, preferably at least 500 cPs, preferably at least 1000 cPs, without causing gel formation, and causes the mixture to remain in a fluid state or stay fluid. Preferably, the thickener, when homogeneously added in an amount of 0.3 wt% to a mixture of 50 wt% water / 50 wt% glycerol at 25°C, causes a viscosity of 0.1°C without causing gel formation. -1 This refers to a compound that, at a shear rate, increases viscosity by at least 2 times, at least 5 times, at least 10 times, or at least 100 times compared to before addition, and which keeps the mixture fluid or preserved.

[0249] The viscosity values ​​listed herein can be measured using a Brookfield RVT viscometer, rotating a disk-type RV#2 spindle at a speed of 6 revolutions per minute (rpm) at 25°C.

[0250] The gel composition preferably contains a thickening agent in an amount ranging from about 0.2% to about 5% by weight. Preferably, the composition contains a thickening agent in an amount ranging from about 0.5% to about 3% by weight. Preferably, the composition contains a thickening agent in an amount ranging from about 0.5% to about 2% by weight. Preferably, the composition contains a thickening agent in an amount ranging from about 1% to about 2% by weight.

[0251] The thickener may contain one or more of the following: xanthan gum, carboxymethylcellulose, microcrystalline cellulose, methylcellulose, gum arabic, guar gum, lambda carrageenan, or starch. It is preferable that the thickener contains xanthan gum.

[0252] The gel composition may contain xanthan gum in an amount ranging from about 0.2% to about 5% by weight. Preferably, the xanthan gum may be in an amount ranging from about 0.5% to about 3% by weight. Preferably, the xanthan gum may be in an amount ranging from about 0.5% to about 2% by weight. Preferably, the xanthan gum may be in an amount ranging from about 1% to about 2% by weight.

[0253] The gel composition may contain carboxymethylcellulose in an amount ranging from about 0.2% to about 5% by weight. Preferably, the carboxymethylcellulose may be in an amount ranging from about 0.5% to about 3% by weight. Preferably, the carboxymethylcellulose may be in an amount ranging from about 0.5% to about 2% by weight. Preferably, the carboxymethylcellulose may be in an amount ranging from about 1% to about 2% by weight.

[0254] The gel composition may contain microcrystalline cellulose in an amount ranging from about 0.2% to about 5% by weight. Preferably, the microcrystalline cellulose may be in an amount ranging from about 0.5% to about 3% by weight. Preferably, the microcrystalline cellulose may be in an amount ranging from about 0.5% to about 2% by weight. Preferably, the microcrystalline cellulose may be in an amount ranging from about 1% to about 2% by weight.

[0255] The gel composition may contain methylcellulose in an amount ranging from about 0.2% to about 5% by weight. Preferably, the methylcellulose may be in an amount ranging from about 0.5% to about 3% by weight. Preferably, the methylcellulose may be in an amount ranging from about 0.5% to about 2% by weight. Preferably, the methylcellulose may be in an amount ranging from about 1% to about 2% by weight.

[0256] The gel composition may contain gum arabic in an amount ranging from about 0.2% to about 5% by weight. Preferably, the amount of gum arabic may be in the range of about 0.5% to about 3% by weight. Preferably, the amount of gum arabic may be in the range of about 0.5% to about 2% by weight. Preferably, the amount of gum arabic may be in the range of about 1% to about 2% by weight.

[0257] The gel composition may contain guar gum in an amount ranging from about 0.2% to about 5% by weight. Preferably, the amount of guar gum may be in the range of about 0.5% to about 3% by weight. Preferably, the amount of guar gum may be in the range of about 0.5% to about 2% by weight. Preferably, the amount of guar gum may be in the range of about 1% to about 2% by weight.

[0258] The gel composition may contain lambda carrageenan in an amount ranging from about 0.2% to about 5% by weight. Preferably, the lambda carrageenan may be in an amount ranging from about 0.5% to about 3% by weight. Preferably, the lambda carrageenan may be in an amount ranging from about 0.5% to about 2% by weight. Preferably, the lambda carrageenan may be in an amount ranging from about 1% to about 2% by weight.

[0259] The gel composition may contain starch in an amount ranging from about 0.2% to about 5% by weight. Preferably, the starch may be in an amount ranging from about 0.5% to about 3% by weight. Preferably, the starch may be in an amount ranging from about 0.5% to about 2% by weight. Preferably, the starch may be in an amount ranging from about 1% to about 2% by weight.

[0260] The gel composition may further contain divalent cations. Preferably, the divalent cations include calcium ions such as calcium lactate in the solution. Divalent cations (such as calcium ions) can assist in gel formation in compositions containing gelling agents, such as ion-crosslinking gelling agents. Ionic effects may assist in gel formation. Divalent cations may be present in the gel composition in the range of about 0.1 to about 1 weight percent, or about 0.5 weight percent.

[0261] The gel composition may further contain an acid. The acid may contain a carboxylic acid. The carboxylic acid may contain a ketone group. Preferably, the carboxylic acid may contain a ketone group having less than 10 carbon atoms, such as levulinic acid or lactic acid, or less than 6 carbon atoms or less than 4 carbonate atoms. Preferably, this carboxylic acid has three carbon atoms (such as lactic acid). Surprisingly, lactic acid improves the stability of the gel composition to a greater extent than similar carboxylic acids. The carboxylic acid may assist in gel formation. The carboxylic acid may reduce changes in the concentration of alkaloid compounds, or cannabinoid compounds, or both, in the gel composition during storage. The carboxylic acid may reduce changes in the nicotine concentration in the gel composition during storage.

[0262] The gel composition may contain a carboxylic acid in an amount ranging from about 0.1% to about 5% by weight. Preferably, the carboxylic acid may be in the range of about 0.5% to about 3% by weight. Preferably, the carboxylic acid may be in the range of about 0.5% to about 2% by weight. Preferably, the carboxylic acid may be in the range of about 1% to about 2% by weight.

[0263] The gel composition may contain lactic acid in an amount ranging from about 0.1% to about 5% by weight. Preferably, the lactic acid may be in an amount ranging from about 0.5% to about 3% by weight. Preferably, the lactic acid may be in an amount ranging from about 0.5% to about 2% by weight. Preferably, the lactic acid may be in an amount ranging from about 1% to about 2% by weight.

[0264] The gel composition may contain levulinic acid in an amount ranging from about 0.1% to about 5% by weight. Preferably, the levulinic acid may be in an amount ranging from about 0.5% to about 3% by weight. Preferably, the levulinic acid may be in an amount ranging from about 0.5% to about 2% by weight. Preferably, the levulinic acid may be in an amount ranging from about 1% to about 2% by weight.

[0265] The gel composition preferably contains some water. The gel composition is more stable when it contains some water. The gel composition preferably contains at least about 1 weight percent, or at least about 2 weight percent, or at least about 5 weight percent of water. The gel composition preferably contains at least about 10 weight percent, or at least about 15 weight percent of water.

[0266] The gel composition preferably contains about 8% to about 32% by weight of water. The gel composition preferably contains about 15% to about 25% by weight of water. The gel composition preferably contains about 18% to about 22% by weight of water. The gel composition preferably contains about 20% by weight of water.

[0267] Preferably, the aerosol generating substrate contains about 150 mg to about 350 mg of gel composition.

[0268] Preferably, in embodiments comprising a gel composition, the aerosol generating substrate comprises a porous medium filled with the gel composition. The advantage of a porous medium loaded with a gel composition is that the gel composition is retained within the porous medium, which can aid in the manufacture, storage, or transport of the gel composition. This can help maintain the desired shape of the gel composition, particularly during manufacture, transport, or use.

[0269] The term "porous" is used herein to refer to a material that provides multiple pores or openings that allow air to pass through the material.

[0270] The porous medium may be any suitable porous material that can hold or retain the gel composition. Ideally, the porous medium can allow the gel composition to move therein. In certain embodiments, the porous medium includes natural materials, synthetic, or semi-synthetic, or combinations thereof. In certain embodiments, the porous medium includes sheet materials, foams, or fibers, such as cotton fibers, or combinations thereof. In certain embodiments, the porous medium includes woven fabrics, non-woven fabrics, or extruded materials, or combinations thereof. The porous medium preferably includes cotton, paper, viscose, PLA, or cellulose acetate, or combinations thereof. The porous medium preferably includes a sheet material, such as cotton or cellulose acetate. In a particularly preferred embodiment, the porous medium includes a sheet made from cotton fibers.

[0271] The porous medium used in the present invention may be crimped or shredded. In a preferred embodiment, the porous medium is crimped. In an alternative embodiment, the porous medium includes shredded porous medium. The crimping or shredding process can be before or after loading the gel composition.

[0272] The crimping of the sheet material has the advantage of improving the structure and allowing passages through the structure. The passages through the crimped sheet material assist in the loading of the gel, the retention of the gel, and the passage of fluid through the crimped sheet material. Thus, there is an advantage in using a crimped sheet material as the porous medium.

[0273] Shredding can give a high surface area to volume ratio to the medium, allowing the gel to be easily absorbed.

[0274] In certain embodiments, the sheet material is a composite material. The sheet material is preferably porous. The sheet material can assist in the production of tubular elements containing gel. The sheet material can assist in the introduction of activators into tubular elements containing gel. The sheet material may help in stabilizing the structure of tubular elements containing gel. The sheet material can assist in the transport or storage of gel. The use of the sheet material allows, for example, to add structure to a porous medium by crimping the sheet material, or assists in such addition.

[0275] The porous medium can be thread. Thread may include, for example, cotton, paper, or acetate thread. Thread may also be loaded with gel, like any other porous medium. An advantage of using thread as a porous medium is that it can aid in ease of manufacture.

[0276] The threads may be loaded with gel by any known means. The threads may be simply coated with gel, or they may be impregnated with gel. In manufacturing, the threads may be impregnated with gel and stored ready for immediate use so that they can be included in the assembly of tubular elements.

[0277] The porous medium loaded with the gel composition is preferably provided within a tubular element that forms part of an aerosol-generating article. Ideally, the tubular element is longer in its longitudinal direction than in its width, but this is not necessarily required, as it may be part of a multi-component item where its longitudinal direction is longer than its width. Typically, the tubular element is cylindrical, but this is not necessarily required. For example, the tubular element may have an elliptical, triangular, rectangular, or other polygonal or irregular cross-section.

[0278] The tubular element preferably includes a first longitudinal passage. The tubular element is preferably formed from a wrapper defining the first longitudinal passage. The wrapper is preferably a water-resistant wrapper. This water resistance of the wrapper can be achieved by using a water-resistant material or by treating the material of the wrapper. This can be achieved by treating one or both sides of the wrapper. Being water-resistant can help not lose structure, hardness, or rigidity. This can also help prevent leakage of gel or liquid, especially when using a gel in a fluid structure.

[0279] Preferably, as described above, in embodiments in which the rod of the aerosol generating substrate includes a gel composition, the downstream section of the aerosol generating article comprises an aerosol cooling element having a length of less than 10 millimeters. It has been found that using a relatively short aerosol cooling element in combination with the gel composition optimizes the delivery of aerosols to consumers.

[0280] Embodiments of the present invention in which the rod of the aerosol generating substrate contains the above-described gel composition preferably include an upstream element upstream of the rod of the aerosol generating substrate. In this case, the upstream element advantageously prevents physical contact with the gel composition. The upstream element can also advantageously compensate for any potential reduction in RTD due to evaporation of the gel composition when the rod of the aerosol generating substrate is heated during use, for example.

[0281] In certain preferred embodiments of the present invention, the elongated susceptor element is substantially longitudinally positioned within the rod of the aerosol generating substrate and is in thermal contact with the aerosol generating substrate.

[0282] As used herein in relation to the present invention, the term "susceptor element" refers to a material capable of converting electromagnetic energy into heat. When located in a fluctuating electromagnetic field, induced eddy currents in the susceptor element cause heating of the susceptor element. When an elongated susceptor element is located in thermal contact with an aerosol-generating substrate, the aerosol-generating substrate is heated by the susceptor element.

[0283] When used to describe a susceptor element, the term "elongated" means that the susceptor element has a length dimension that is greater than its width dimension or thickness dimension, for example, greater than twice its width dimension or thickness dimension.

[0284] The susceptor element is positioned substantially longitudinally within the rod. This means that the length dimension of the elongated susceptor element is positioned approximately parallel to the longitudinal direction of the rod, for example, within ±10 degrees from parallel to the longitudinal direction of the rod. In a preferred embodiment, the elongated susceptor element may be positioned radially centrally within the rod and extend along the longitudinal axis of the rod.

[0285] Preferably, the susceptor element extends over the entire length of the rod of the aerosol generating article to the downstream end. In some embodiments, the susceptor element may extend over the entire length of the rod of the aerosol generating article to the upstream end. In a particularly preferred embodiment, the susceptor element has substantially the same length as the rod of the aerosol generating substrate and extends from the upstream end of the rod to the downstream end of the rod.

[0286] The susceptor element is preferably in the form of a pin, rod, strip, or blade.

[0287] The susceptor element preferably has a length of about 5 mm to about 15 mm, for example, about 6 mm to about 12 mm, or about 8 mm to about 10 mm.

[0288] The ratio between the length of the susceptor element and the total length of the aerosol-generating article substrate can be from about 0.2 to about 0.35.

[0289] Preferably, the ratio between the length of the susceptor element and the total length of the aerosol-generating article substrate is at least about 0.22, more preferably at least about 0.24, even more preferably at least about 0.26. The ratio between the length of the susceptor element and the total length of the aerosol-generating article substrate is preferably less than about 0.34, more preferably less than about 0.32, even more preferably less than about 0.3.

[0290] In some embodiments, the ratio between the length of the susceptor element and the total length of the aerosol-generating article substrate is preferably from about 0.22 to about 0.34, more preferably from about 0.24 to about 0.34, even more preferably from about 0.26 to about 0.34. In other embodiments, the ratio between the length of the susceptor element and the total length of the aerosol-generating article substrate is preferably from about 0.22 to about 0.32, more preferably from about 0.24 to about 0.32, even more preferably from about 0.26 to about 0.32. In further embodiments, the ratio between the length of the susceptor element and the total length of the aerosol-generating article substrate is preferably from about 0.22 to about 0.3, more preferably from about 0.24 to about 0.3, even more preferably from about 0.26 to about 0.3.

[0291] In a particularly preferred embodiment, the ratio between the length of the susceptor element and the total length of the aerosol-generating article substrate is about 0.27.

[0292] The susceptor element preferably has a width of from about 1 millimeter to about 5 millimeters.

[0293] The susceptor element can generally have a thickness of from about 0.01 millimeter to about 2 millimeters, for example from about 0.5 millimeter to about 2 millimeters. In some embodiments, the susceptor element preferably has a thickness of from about 10 micrometers to about 500 micrometers, more preferably from about 10 micrometers to about 100 micrometers.

[0294] If the susceptor element has a certain cross-section, for example a circular cross-section, it has a preferred width or diameter of about 1 mm to about 5 mm.

[0295] If the susceptor element has the form of a strip or blade, the strip or blade preferably has a rectangular shape with a width of about 2 mm to about 8 mm, more preferably about 3 mm to about 5 mm. As an example, a susceptor element in the form of a blade strip may have a width of about 4 mm.

[0296] If the susceptor element has the form of a strip or blade, the strip or blade is preferably rectangular in shape and has a thickness of about 0.03 mm to about 0.15 mm, more preferably about 0.05 mm to about 0.09 mm. As an example, a susceptor element in the form of a blade strip may have a thickness of about 0.07 mm.

[0297] In a preferred embodiment, the elongated susceptor element is in the form of a strip or blade, preferably having a rectangular shape and a thickness of about 55 micrometers to about 65 micrometers.

[0298] More preferably, the elongated susceptor element has a thickness of about 57 micrometers to about 63 micrometers. Even more preferably, the elongated susceptor element has a thickness of about 58 micrometers to about 62 micrometers. In a particularly preferred embodiment, the elongated susceptor element has a thickness of about 60 micrometers.

[0299] The elongated susceptor element is preferably the same length as or shorter than the aerosol-generating substrate.

[0300] The susceptor element can be formed from any material that can be inductively heated to a temperature sufficient to generate aerosols from the aerosol-generating substrate. Preferred susceptor elements include metals or carbon.

[0301] Preferred susceptor elements may include or consist of ferromagnetic materials, such as ferromagnetic alloys, ferrite iron, ferromagnetic steel, or stainless steel. Suitable susceptor elements may be aluminum, or contain aluminum. Preferred susceptor elements may be formed from 400 series stainless steel, such as Grade 410, Grade 420, or Grade 430 stainless steel. Different materials dissipate different amounts of energy when positioned in an electromagnetic field having similar values ​​of frequency and magnetic field strength.

[0302] Thus, any of the parameters of the susceptor element, such as the type of material, length, width, and thickness, may be varied to provide the desired power distribution within a known electromagnetic field. A preferred susceptor element may be heated to a temperature above 250 degrees Celsius.

[0303] A suitable susceptor element may include a non-metallic core having a metal layer disposed on top of a non-metallic core, for example, a metal track formed on the surface of a ceramic core. The susceptor element may have a protective outer layer, such as a protective ceramic layer or protective glass layer that encloses the susceptor element. The susceptor element may have a protective coating formed of glass, ceramic, or an inert metal formed on the core of the susceptor element material.

[0304] The susceptor element is positioned in thermal contact with the aerosol-generating substrate. Thus, when the temperature of the susceptor element increases, the aerosol-generating substrate is heated, and an aerosol is formed. Preferably, the susceptor element is positioned, for example, within the aerosol-generating substrate, in direct physical contact with the aerosol-generating substrate.

[0305] The susceptor element may be a multi-material susceptor element and may comprise a first susceptor element material and a second susceptor element material. The first susceptor element material is physically in close contact with the second susceptor element material. The second susceptor element material preferably has a Curie temperature lower than 500 degrees Celsius. The first susceptor element material is preferably used primarily to heat the susceptor element when it is placed in a fluctuating electromagnetic field. Any suitable material may be used. For example, the first susceptor element material may be aluminum or an iron-based material such as stainless steel. The second susceptor element material is preferably used primarily to indicate when the susceptor element has reached a specific temperature, which is the Curie temperature of the second susceptor element material. The Curie temperature of the second susceptor element material can be used to regulate the temperature of the entire susceptor element during operation. Therefore, the Curie temperature of the second susceptor element material should be below the ignition point of the aerosol-generating substrate. Suitable materials for the second susceptor element material may include nickel and certain nickel alloys.

[0306] By providing a susceptor element having at least first and second susceptor element materials, either a second susceptor element material having a Curie temperature or a first susceptor element material not having a Curie temperature, or by providing first and second susceptor element materials having different first and second Curie temperatures, the heating of the aerosol generating substrate and the temperature control of that heating can be separated. The first susceptor element material is preferably a magnetic material having a Curie temperature of over 500 degrees Celsius. From the viewpoint of heating efficiency, it is desirable that the Curie temperature of the first susceptor element material exceeds any maximum temperature to which the susceptor element can be heated. The second Curie temperature may be selected to be preferably lower than 400 degrees Celsius, preferably lower than 380 degrees Celsius, or lower than 360 degrees Celsius. The second susceptor element material is preferably a magnetic material selected to have a second Curie temperature that is substantially the same as the desired maximum heating temperature. In other words, the second Curie temperature is preferably approximately the same as the temperature at which the susceptor element should be heated to generate aerosols from the aerosol-generating substrate. The second Curie temperature may be, for example, in the range of 200 to 400 degrees Celsius, or in the range of 250 to 360 degrees Celsius. The second Curie temperature of the second susceptor element material may be selected such that, when heated by a susceptor element having a temperature equal to the second Curie temperature, the overall average temperature of the aerosol-generating substrate does not exceed 240 degrees Celsius.

[0307] The aerosol-generating article of the present invention may further comprise an upstream element located upstream of and adjacent to the aerosol-generating substrate, wherein the upstream section comprises at least one upstream element. The upstream element advantageously prevents direct physical contact with the upstream end of the aerosol-generating substrate. In particular, if the aerosol-generating substrate comprises a susceptor element, the upstream element can prevent direct physical contact with the upstream end of the susceptor element. This helps prevent displacement or deformation of the susceptor element during handling or transport of the aerosol-generating article. This, in turn, helps to fix the shape and position of the susceptor element. Furthermore, the presence of the upstream element may be advantageous, for example, when the substrate contains particulate plant material, in order to prevent any loss of the substrate.

[0308] The upstream element may also provide an improved appearance to the upstream end of the aerosol-generating article. Furthermore, if desired, the upstream element may be used to provide information about the aerosol-generating article, such as the brand, flavor, content, or details of the aerosol generator in which the article is intended to be used.

[0309] The upstream element may be a porous plug element. A porous plug element is preferable as it does not alter the draw resistance of the aerosol-generating article. The upstream element preferably has a porosity of at least about 50 percent in the longitudinal direction of the aerosol-generating article. More preferably, the upstream element has a porosity of about 50 percent to about 90 percent in the longitudinal direction. The longitudinal porosity of the upstream element is defined by the ratio of the cross-sectional area of ​​the material forming the upstream element to the internal cross-sectional area of ​​the aerosol-generating article at the location of the upstream element.

[0310] The upstream element may be made of a porous material or may have multiple openings. This can be achieved, for example, by laser drilling. Preferably, the multiple openings are uniformly distributed across the entire cross-section of the upstream element.

[0311] The porosity or permeability of the upstream element can be advantageously varied to provide the desired overall draw resistance of the aerosol-generating article.

[0312] The RTD of the upstream element is preferably at least about 5 milliH2O. More preferably, the RTD of the upstream element is at least about 10 milliH2O. Even more preferably, the RTD of the upstream element is at least about 15 milliH2O. In a particularly preferred embodiment, the RTD of the upstream element is at least about 20 milliH2O.

[0313] Preferably, the RTD of the upstream element is about 80 mmH2O or less. More preferably, the RTD of the upstream element is about 60 mmH2O or less. Even more preferably, the RTD of the upstream element is about 40 mmH2O or less.

[0314] In some embodiments, the RTD of the upstream element is about 5 mmH2O to about 80 mmH2O, preferably about 10 mmH2O to about 80 mmH2O, more preferably about 15 mmH2O to about 80 mmH2O, and even more preferably about 20 mmH2O to about 80 mmH2O. In other embodiments, the RTD of the upstream element is about 5 mmH2O to about 60 mmH2O, preferably about 10 mmH2O to about 60 mmH2O, more preferably about 15 mmH2O to about 60 mmH2O, and even more preferably about 20 mmH2O to about 60 mmH2O. In further embodiments, the RTD of the upstream element is about 5 mmH2O to about 40 mmH2O, preferably about 10 mmH2O to about 40 mmH2O, more preferably about 15 mmH2O to about 40 mmH2O, and even more preferably about 20 mmH2O to about 40 mmH2O.

[0315] The RTD of the upstream element is preferably greater than that of the mouthpiece element. Preferably, the RTD of the upstream element is at least 1.5 times that of the mouthpiece, more preferably at least 2 times that of the mouthpiece, and more preferably at least 2.5 times that of the mouthpiece element. This advantageously provides a larger proportion of the overall RTD of the aerosol-generating article upstream of the rod of the aerosol-generating substrate. This allows for minimizing the RTD of the mouthpiece element and, if necessary, also minimizing the filtration effect on the aerosol.

[0316] In alternative embodiments, the upstream element may be formed from a material that is impermeable to air. In such embodiments, the aerosol generating article may be configured such that air flows into the rods of the aerosol generating substrate through a suitable ventilation means provided within the wrapper.

[0317] The upstream element may be made of any material suitable for use in an aerosol generating article. The upstream element may be made of the same material used for one of the other components of the aerosol generating article, such as a mouthpiece, cooling element, or support element. Suitable materials for the upstream element include filter materials, ceramics, polymer materials, cellulose acetate, cardboard, zeolite, or aerosol generating substrates. The upstream element is preferably formed from a cellulose acetate plug.

[0318] The upstream element is preferably made of a heat-resistant material. For example, the upstream element is preferably made of a material that can withstand temperatures up to 350 degrees Celsius. This ensures that the upstream element is not adversely affected by the heating means used to heat the aerosol generating substrate.

[0319] The upstream element preferably has a diameter approximately equal to the diameter of the aerosol-generating article.

[0320] The upstream element preferably has a length of about 1 mm to about 10 mm, more preferably about 3 mm to about 8 mm, and more preferably about 4 mm to about 6 mm. In a particularly preferred embodiment, the upstream element has a length of about 5 mm. The length of the upstream element can be advantageously varied to provide the desired overall length of the aerosol generating article. For example, if it is desirable to reduce the length of one of the other components of the aerosol generating article, the length of the upstream element can be increased to maintain the same overall length of the article.

[0321] The upstream element preferably has a substantially homogeneous structure. For example, the upstream element may have a substantially homogeneous texture and appearance. The upstream element may, for example, have a continuous, regular surface over its entire cross-section. The upstream element may, for example, not have recognizable symmetry.

[0322] The upstream element is preferably surrounded by a wrapper. The wrapper surrounding the upstream element is preferably a rigid plug wrap, for example, a plug wrap having a basis weight of at least about 80 grams / square meter (gsm), or at least about 100 gsm, or at least about 110 gsm. This provides structural rigidity to the upstream element.

[0323] The aerosol-generating article according to the present invention may have a length of about 35 mm to about 100 mm.

[0324] The total length of the aerosol generating article according to the present invention is preferably at least about 38 millimeters. More preferably, the total length of the aerosol generating article according to the present invention is at least about 40 millimeters. Even more preferably, the total length of the aerosol generating article according to the present invention is at least about 42 millimeters.

[0325] The total length of the aerosol generating article according to the present invention is preferably 70 millimeters or less. More preferably, the total length of the aerosol generating article according to the present invention is preferably 60 millimeters or less. Even more preferably, the total length of the aerosol generating article according to the present invention is preferably 50 millimeters or less.

[0326] In some embodiments, the total length of the aerosol generating article is preferably about 38 mm to about 70 mm, more preferably about 40 mm to about 70 mm, and even more preferably about 42 mm to about 70 mm. In other embodiments, the total length of the aerosol generating article is preferably about 38 mm to about 60 mm, more preferably about 40 mm to about 60 mm, and even more preferably about 42 mm to about 60 mm. In further embodiments, the total length of the aerosol generating article is preferably about 38 mm to about 50 mm, more preferably about 40 mm to about 50 mm, and even more preferably about 42 mm to about 50 mm. In an exemplary embodiment, the total length of the aerosol generating article is about 45 mm.

[0327] The aerosol-generating article preferably has an outer diameter of at least 5 mm. The aerosol-generating article preferably has an outer diameter of at least 6 mm. The aerosol-generating article more preferably has an outer diameter of at least 7 mm.

[0328] The aerosol generating article preferably has an outer diameter of about 12 mm or less. More preferably, the aerosol generating article has an outer diameter of about 10 mm or less. Even more preferably, the aerosol generating article has an outer diameter of about 8 mm or less.

[0329] In some embodiments, the aerosol-generating article has an outer diameter of about 5 mm to about 12 mm, preferably about 6 mm to about 12 mm, and more preferably about 7 mm to about 12 mm. In other embodiments, the aerosol-generating article has an outer diameter of about 5 mm to about 10 mm, preferably about 6 mm to about 10 mm, and more preferably about 7 mm to about 10 mm. In further embodiments, the aerosol-generating article has an outer diameter of about 5 mm to about 8 mm, preferably about 6 mm to about 8 mm, and more preferably about 7 mm to about 8 mm.

[0330] In certain preferred embodiments of the present invention, the diameter (D) of the aerosol-generating article at the mouth end is ME ) is the diameter (D) of the aerosol-generating article at the distal end. DE (Preferably) greater than ). More specifically, the ratio (D) between the diameter of the aerosol generating article at the oral end and the diameter of the aerosol generating article at the distal end. ME / D DE ) is (preferably) at least about 1.005.

[0331] Preferably, the ratio (D) between the diameter of the aerosol-generating article at the mouth end and the diameter of the aerosol-generating article at the distal end. ME / D DE ) is (preferably) at least about 1.01. More preferably, the ratio (D) between the diameter of the aerosol generating article at the mouth end and the diameter of the aerosol generating article at the distal end is ME / D DE The ratio (D) between the diameter of the aerosol-generating article at the oral end and the diameter of the aerosol-generating article at the distal end is at least about 1.02. More preferably, the ratio (D) between the diameter of the aerosol-generating article at the oral end and the diameter of the aerosol-generating article at the distal end is at least about 1.02. ME / D DE ) is at least about 1.05.

[0332] The ratio of the diameter of the aerosol-generating object at the oral end to the diameter of the aerosol-generating object at the distal end (D ME / D DEThe ratio (D) between the diameter of the aerosol generating article at the mouth end and the diameter of the aerosol generating article at the distal end is preferably about 1.30 or less. ME / D DE The ratio (D) between the diameter of the aerosol generating article at the oral end and the diameter of the aerosol generating article at the distal end is approximately 1.25 or less. More preferably, the ratio (D) between the diameter of the aerosol generating article at the oral end and the diameter of the aerosol generating article at the distal end is approximately 1.25 or less. ME / D DE ) is about 1.20 or less. In a particularly preferred embodiment, the ratio (D) between the diameter of the aerosol generating article at the mouth end and the diameter of the aerosol generating article at the distal end is about 1.20 or less. ME / D DE ) is 1.15 or 1.10 or less.

[0333] In some preferred embodiments, the ratio (D) between the diameter of the aerosol-generating article at the oral end and the diameter of the aerosol-generating article at the distal end is ME / D DE The ratio is approximately 1.01 to 1.30, more preferably 1.02 to 1.30, and even more preferably 1.05 to 1.30.

[0334] In other embodiments, the ratio (D) between the diameter of the aerosol-generating article at the oral end and the diameter of the aerosol-generating article at the distal end is ME / D DE The ratio (D) is approximately 1.01 to 1.25, more preferably 1.02 to 1.25, and even more preferably 1.05 to 1.25. In further embodiments, the ratio (D) between the diameter of the aerosol generating article at the oral end and the diameter of the aerosol generating article at the distal end is ME / D DE The ratio (D) is approximately 1.01 to 1.20, more preferably 1.02 to 1.20, and even more preferably 1.05 to 1.20. In further embodiments, the ratio (D) between the diameter of the aerosol generating article at the mouth end and the diameter of the aerosol generating article at the distal end is also specified. ME / D DE The ratio is approximately 1.01 to 1.15, more preferably 1.02 to 1.15, and even more preferably 1.05 to 1.15.

[0335] For example, the outer diameter of the article may be substantially constant over the distal end of the article extending at least about 5 millimeters or at least about 10 millimeters from the distal end of the aerosol-generating article. Alternatively, the outer diameter of the article may be tapered over the distal portion of the article extending at least about 5 millimeters or at least about 10 millimeters from the distal end.

[0336] In certain preferred embodiments of the present invention, as described above, the elements of the aerosol generating article are arranged such that the center of mass of the aerosol generating article is at least about 60 percent along the length of the aerosol generating article from the downstream end. More preferably, the elements of the aerosol generating article are arranged such that the center of mass of the aerosol generating article is at least about 62 percent along the length of the aerosol generating article from the downstream end, and more preferably, at least about 65 percent along the length of the aerosol generating article from the downstream end.

[0337] The center of mass is preferably about 70 percent or less along the length of the aerosol-generating article from the downstream end.

[0338] By providing an arrangement of elements that gives the center of mass closer to the upstream end than the downstream end, an aerosol-generating article with a weight imbalance having a heavier upstream end is created. This weight imbalance can advantageously provide tactile feedback to the consumer, allowing them to distinguish between the upstream and downstream ends and insert the correct end into the aerosol generator. This may be particularly beneficial when the upstream elements are provided such that the upstream and downstream ends of the aerosol-generating article are visually similar to each other.

[0339] In embodiments of the aerosol generating article according to the present invention, both an aerosol cooling element and a support element are present, which are preferably wrapped together in a combined wrapper. The combined wrapper surrounds the aerosol cooling element and the support element, but does not surround further downstream elements such as a mouthpiece element.

[0340] In these embodiments, the aerosol cooling element and support element are assembled before being surrounded by the combined wrapper, and then further assembled with the mouthpiece segment.

[0341] From a manufacturing perspective, this is advantageous in that it allows for the assembly of shorter aerosol-generating articles.

[0342] Generally, dealing with individual elements whose length is smaller than their diameter can be challenging. For example, for an element with a diameter of 7 millimeters, a length of approximately 7 millimeters represents a desirable threshold where it remains constant. However, a 10-millimeter aerosol cooling element can be combined with pairs of 7-millimeter support elements on each side (and potentially with other elements such as rods of the aerosol generating substrate) to provide a 24-millimeter hollow segment, which can then be cut into two intermediate hollow sections of 12 millimeters each.

[0343] In a particularly preferred embodiment, the other components of the aerosol generating article are individually enclosed by their own wrappers. In other words, the upstream element, the rod of the aerosol generating substrate, the support element, and the aerosol cooling element are all individually wrapped. The support element and the aerosol cooling element are combined to form an intermediate hollow section. This is achieved by wrapping the support element and the aerosol cooling element in a combined wrapper. The upstream element, the rod of the aerosol generating substrate, and the intermediate hollow section are then combined with the outer wrapper. They are then combined with a mouthpiece element, which has its own wrapper, using chipping paper.

[0344] Preferably, at least one of the components of the aerosol-generating article is wrapped in a hydrophobic wrapper.

[0345] The term "hydrophobic" refers to a surface that exhibits water-repellent properties. One useful way to determine this is by measuring the water contact angle. The water contact angle is the angle conventionally measured through a liquid, where the liquid / vapor interface intersects with the solid surface. This quantifies the wettability of a solid surface by a liquid via Young's equation. Hydrophobicity or the water contact angle may also be determined using the TAPPI T558 test method, and the result is expressed as the interfacial contact angle and reported in degrees, which can range from approximately zero to approximately 180 degrees.

[0346] In a preferred embodiment, the hydrophobic wrapper includes a paper layer having a water contact angle of about 30 degrees or more, preferably about 35 degrees or more, or about 40 degrees or more, or about 45 degrees or more.

[0347] For example, the paper layer may contain PVOH (polyvinyl alcohol) or silicone. PVOH may be applied to the paper layer as a surface coating, or the paper layer may include a surface treatment containing PVOH or silicone.

[0348] In a particularly preferred embodiment, the aerosol generating article according to the present invention comprises, in a linear continuous arrangement, an upstream element, a rod of an aerosol generating substrate located immediately downstream of the upstream element, a support element located immediately downstream of the rod of the aerosol generating substrate, an aerosol cooling element located immediately downstream of the support element, a mouthpiece element located immediately downstream of the aerosol cooling element, and an outer wrapper surrounding the upstream element, the support element, the aerosol cooling element, and the mouthpiece element.

[0349] More specifically, the rod of the aerosol generating substrate may be in contact with the upstream element. The support element may be in contact with the rod of the aerosol generating substrate. The aerosol cooling element may be in contact with the support element. The mouthpiece element may be in contact with the aerosol cooling element.

[0350] The aerosol-generating article has a substantially cylindrical shape and an outer diameter of approximately 7.25 millimeters.

[0351] The upstream element has a length of approximately 5 mm, the rod of the aerosol generating article has a length of approximately 12 mm, the support element has a length of approximately 8 mm, and the mouthpiece element has a length of approximately 12 mm. Therefore, the total length of the aerosol generating article is approximately 45 mm.

[0352] The upstream element is in the form of a cellulose acetate plug encased in a rigid plug wrap.

[0353] The aerosol generating article comprises an elongated susceptor element substantially arranged longitudinally within the rod of the aerosol generating substrate and in thermal contact with the aerosol generating substrate. The susceptor element is in the form of a strip or blade and has a length substantially equal to the length of the rod of the aerosol generating substrate and a thickness of about 60 micrometers.

[0354] The support element is in the form of a hollow cellulose acetate tube with an inner diameter of approximately 1.9 mm. Therefore, the thickness of the peripheral wall of the support element is approximately 2.675 mm.

[0355] The aerosol cooling element is in the form of a finer, hollow cellulose acetate tube with an inner diameter of approximately 3.25 mm. Therefore, the thickness of the peripheral wall of the aerosol cooling element is approximately 2 mm.

[0356] The mouthpiece is in the form of low-density cellulose acetate filter segments.

[0357] The rod of the aerosol generating substrate includes at least one of the above-mentioned types of aerosol generating substrates, such as homogenized tobacco containing particles of plants other than tobacco, a gel formulation, or homogenized plant material. [Brief explanation of the drawing]

[0358] In the following, the present invention will be further described with reference to the attached drawing Figure 1, which shows a schematic side cross-sectional view of an aerosol generating article according to the present invention.

[0359] [Figure 1] The aerosol generating article 10 shown in Figure 1 comprises a rod 12 of an aerosol generating substrate 12 and a downstream section 14 located downstream of the rod 12 of the aerosol generating substrate. Furthermore, the aerosol generating article 10 includes an upstream section 16 located upstream of the rod 12 of the aerosol generating substrate. Thus, the aerosol generating article 10 may extend from an upstream or distal end 18 to a downstream or oral end 20. [Modes for carrying out the invention]

[0360] The aerosol-generating article has a total length of approximately 45 millimeters.

[0361] The downstream section 14 includes a support element 22 located immediately downstream of the rod 12 of the aerosol generating substrate, and the support element 22 is longitudinally aligned with the rod 12. In the embodiment of Figure 1, the upstream end of the support element 18 abuts against the downstream end of the rod 12 of the aerosol generating substrate. Furthermore, the downstream section 14 includes an aerosol cooling element 24 located immediately downstream of the support element 22, and the aerosol cooling element 24 is longitudinally aligned with the rod 12 and the support element 22. In the embodiment of Figure 1, the upstream end of the aerosol cooling element 24 abuts against the downstream end of the support element 22.

[0362] As will become clear from the following description, the support element 22 and the aerosol cooling element 24 together define the intermediate hollow section 50 of the aerosol generating article 10. Overall, the intermediate hollow section 50 does not contribute substantially to the overall RTD of the aerosol generating article. The RTD of the intermediate hollow section 26 as a whole is substantially 0 mmH2O.

[0363] The support element 22 may include a first hollow tubular segment 26. The first hollow tubular segment 26 is provided in the form of a hollow cylindrical tube made from cellulose acetate. The first hollow tubular segment 26 defines an internal cavity 28 that extends entirely from the upstream end 30 of the first hollow tubular segment 20 to the downstream end 32 of the first hollow tubular segment 20. The internal cavity 28 is substantially empty, and therefore substantially unlimited airflow is possible along the internal cavity 28. The first hollow tubular segment 26, and consequently the support element 22, does not substantially contribute to the overall RTD of the aerosol generating article 10. More specifically, the RTD of the first hollow tubular segment 26 (which is substantially the RTD of the support element 22) is substantially 0 mmH2O.

[0364] The first hollow tubular segment 26 has a length of approximately 8 mm, an outer diameter of approximately 7.25 mm, and an inner diameter of approximately 1.9 mm (D FTS ) has. Therefore, the thickness of the peripheral wall of the first hollow tubular segment 26 is approximately 2.67 millimeters.

[0365] The aerosol cooling element 24 comprises a second hollow tubular segment 34. The second hollow tubular segment 34 is provided in the form of a hollow cylindrical tube made from cellulose acetate. The second hollow tubular segment 34 defines an internal cavity 36 that extends entirely from the upstream end 38 of the second hollow tubular segment 34 to the downstream end 40 of the second hollow tubular segment 34. The internal cavity 36 is substantially empty, and therefore substantially unlimited airflow is possible along the internal cavity 36. The second hollow tubular segment 28, and consequently the aerosol cooling element 24, does not substantially contribute to the overall RTD of the aerosol generating article 10. More specifically, the RTD of the second hollow tubular segment 34 (which is essentially the RTD of the aerosol cooling element 24) is substantially 0 mmH2O.

[0366] The second hollow tubular segment 34 has a length of approximately 8 mm, an outer diameter of approximately 7.25 mm, and an inner diameter of approximately 3.25 mm (D STS) has. Therefore, the thickness of the peripheral wall of the second hollow tubular segment 34 is about 2 millimeters. Therefore, the inner diameter (D) of the first hollow tubular segment 26 is FTS ) and the inner diameter (D) of the second hollow tubular segment 34 STS The ratio between ) is approximately 0.75.

[0367] The aerosol-generating article 10 includes a ventilation zone 60 provided along the second hollow tubular segment 34. More specifically, the ventilation zone is provided approximately 2 millimeters from the upstream end of the second hollow tubular segment 34. The ventilation level of the aerosol-generating article 10 is approximately 25 percent.

[0368] In the embodiment shown in Figure 1, the downstream section 14 further comprises a mouthpiece element 42 located downstream of the intermediate hollow section 50. More specifically, the mouthpiece element 42 is positioned immediately downstream of the aerosol cooling element 24. As shown in the drawing of Figure 1, the upstream end of the mouthpiece element 42 abuts against the downstream end 40 of the aerosol cooling element 18.

[0369] The mouthpiece element 42 is provided in the form of a cylindrical plug made of low-density cellulose acetate.

[0370] The mouthpiece element 42 has a length of approximately 12 mm and an outer diameter of approximately 7.25 mm. The RTD of the mouthpiece element 42 is approximately 12 mm of H2O.

[0371] Rod 12 contains one of the aerosol-generating substrates of the type described above.

[0372] The rod 12 of the aerosol generating substrate has an outer diameter of approximately 7.25 millimeters and a length of approximately 12 millimeters.

[0373] The aerosol generating article 10 further comprises an elongated susceptor element 44 within the rod 12 of the aerosol generating substrate. More specifically, the susceptor element 44 is substantially longitudinally positioned within the aerosol generating substrate so as to be substantially parallel to the longitudinal direction of the rod 12. As shown in the drawing of Figure 1, the susceptor element 44 is positioned radially centrally within the rod and extends effectively along the longitudinal axis of the rod 12.

[0374] The susceptor element 44 extends along the entire length of the rod 12, from its upstream end to its downstream end. In practice, the susceptor element 44 has substantially the same length as the rod 12 of the aerosol generating substrate.

[0375] In the embodiment shown in Figure 1, the susceptor element 44 is provided in the form of a strip, having a length of about 12 millimeters, a thickness of about 60 micrometers, and a width of about 4 millimeters. The upstream section 16 comprises an upstream element 46 located immediately upstream of the rod 12 of the aerosol generating substrate, the upstream element 46 being longitudinally aligned with the rod 12. In the embodiment shown in Figure 1, the downstream end of the upstream element 46 abuts against the upstream end of the rod 12 of the aerosol generating substrate. This advantageously prevents the susceptor element 44 from detaching. Furthermore, this ensures that consumers cannot accidentally come into contact with the heated susceptor element 44 after use.

[0376] The upstream element 46 is supplied in the form of a cylindrical plug of cellulose acetate surrounded by a rigid wrapper. The upstream element 46 has a length of approximately 5 millimeters. The RTD of the upstream element 46 is approximately 30 millimeters of H2O.

Claims

1. An aerosol generating article for generating an inhalable aerosol upon heating, wherein the aerosol generating article is A rod of the aerosol generating substrate, An upstream element provided upstream of the rod of the aerosol generating substrate, A mouthpiece element having a length of at least 10 millimeters, An intermediate hollow section between the rod of the aerosol generating substrate and the mouthpiece element, comprising an aerosol cooling element axially aligned with the mouthpiece element and in contact with the upstream end of the mouthpiece element, wherein the aerosol cooling element comprises a hollow tubular segment having a length of less than 10 millimeters and defining a longitudinal cavity that provides an unlimited flow channel, and the hollow tubular segment comprises an intermediate hollow section having a wall thickness of 1.5 millimeters to 2.5 millimeters, An aerosol generating article in which the length of the mouthpiece element is at least 2 millimeters longer than the length of the aerosol cooling element.

2. The aerosol generating article according to claim 1, wherein the aerosol cooling element includes a ventilation zone provided along the hollow tubular segment of the aerosol cooling element.

3. The aerosol generating article according to claim 1 or 2, wherein the intermediate hollow section further defines a support element between the aerosol cooling element and the rod of the aerosol generating substrate, and the support element includes a hollow tubular segment.

4. The aerosol generating article according to claim 3, wherein the ratio between the inner diameter of the hollow tubular segment of the aerosol cooling element and the inner diameter of the hollow tubular segment of the support element is at least about 1.

25.

5. The aerosol generating article according to any one of claims 1 to 4, wherein the inner diameter of the hollow tubular segment of the aerosol cooling element is at least about 3 millimeters.

6. The draw resistance of the aerosol cooling element is 10 mmH 2 An aerosol-generating article according to any one of claims 1 to 5, wherein the value is less than 0.

7. The aerosol generating article according to any one of claims 1 to 6, wherein the length of the intermediate hollow section is approximately 18 millimeters or less.

8. The lead-off resistor (RTD) of the upstream element is at least 20 mmH 2 An aerosol-generating article according to any one of claims 1 to 7, wherein the article is O.

9. The aerosol generating article according to any one of claims 1 to 8, wherein the draw-out resistance (RTD) of the upstream element is at least twice that of the mouthpiece element.

10. The aerosol generating article according to any one of claims 1 to 9, wherein the length of the mouthpiece element is at least 0.4 times the length of the intermediate hollow section.

11. The aerosol generating article according to any one of claims 1 to 10, wherein the rod of the aerosol generating substrate further comprises an elongated susceptor element extending longitudinally through the rod of the aerosol generating substrate.

12. The aerosol generating article according to any one of claims 1 to 11, wherein the rod of the aerosol generating substrate contains a gel composition.

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