Flame retardant-containing aerosol-generating articles

Abstract

An aerosol-generating article (10, 110) for generating an inhalable aerosol upon heating is provided. The aerosol-generating article (10, 110) includes a rod of aerosol-generating substrate (12), a downstream section (14, 114) located downstream from the rod of aerosol-generating substrate (12), and a wrapper (70) surrounding at least the rod of aerosol-generating substrate (12). The aerosol-generating substrate has a density greater than about 300 milligrams per cubic centimeter, and the wrapper (70) includes a flame-retardant composition including one or more flame-retardant compounds.

Description

[Technical Field]

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

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

[0003] In conventional cigarettes, the consumer inhales air through the proximal end while igniting the distal end of the cigarette. The heat locally generated by the flame and the oxygen in the air drawn in through the cigarette ignites the distal end of the cigarette, and the combustion of the tobacco rod and surrounding wrapper produces inhalable smoke. In contrast, in heated aerosol-generating articles, aerosols are generated by a gentler transfer of heat from a heat source to a physically separated aerosol-generating substrate or material, which may be in contact with, within, around, or downstream of the heat source. During use of the aerosol-generating article, volatile compounds are released from the aerosol-generating substrate by heat transfer from the heat source and entrained in the air drawn in through the aerosol-generating article. As the released compounds cool, they condense to form an aerosol.

[0004] Numerous prior art documents disclose aerosol generators for consuming aerosol-generating articles. Such devices include, for example, electrically heated aerosol generators in which aerosols are generated by heat transfer from one or more electric heater elements of the aerosol generator to the aerosol-generating substrate of a heated aerosol-generating article. For example, electrically heated aerosol generators have been proposed that include internal heater blades adapted to be inserted into an aerosol-generating substrate. Alternatively, inductively exothermic aerosol-generating articles have also been proposed that include an aerosol-generating substrate and a susceptor disposed within the aerosol-generating substrate.

[0005] Aerosol-generating articles in which the tobacco-containing substrate is heated rather than burned present several challenges not encountered with conventional smoking articles. The tobacco-containing substrate is typically heated to a temperature significantly lower than that reached at the pre-combustion stage of a conventional cigarette. However, the heating temperature is not too low, which can affect nicotine release from the tobacco-containing substrate and nicotine delivery to the consumer. Furthermore, to maximize heat transfer efficiency, it is desirable that the heat source be positioned as close as possible to, and preferably in contact with, the aerosol-generating substrate.

[0006] Therefore, in existing aerosol-generating articles designed to be heated by a heater blade inserted into the aerosol-generating substrate or by a susceptor placed within the aerosol-generating substrate, the aerosol-generating substrate is typically surrounded by a wrapper combining a metal foil, such as aluminum foil, with a paper layer. Thus, the metal layer sandwiched between the aerosol-generating substrate and the paper wrapper acts as a heat shield, preventing the paper wrapper from burning or carbonizing during use. This is desirable to enhance the safety of using the aerosol-generating article and prevent the delivery of paper combustion products or paper pyrolysis products to the consumer during use. However, including one such metal shield makes the manufacturing process more complex and expensive, and may increase the environmental impact of the aerosol-generating article when it is disposed of after use. Furthermore, since the original visual impact of the aerosol-generating article is substantially preserved during use, it can be difficult to determine whether the aerosol-generating article is being used effectively.

[0007] Therefore, it is desirable to provide novel and improved aerosol generating articles that are easier to dispose of, have a reduced environmental impact, and are adapted to prevent burning or carbonization of the article during use. Secondly, there is a generally perceived need for novel and improved aerosol generating articles that substantially prevent misuse of the article, such as so that the article can only be used correctly in an aerosol generating device adapted to heat the aerosol generating substrate, and not used as a conventional cigarette. Furthermore, it is also desirable to provide a single such aerosol generating article that can be manufactured efficiently and quickly, preferably without requiring extensive modifications to existing equipment.

[0008] 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. [Overview of the Initiative]

[0009] This disclosure relates to an aerosol generating article for generating an inhalable aerosol upon heating, comprising a rod of an aerosol generating substrate. The aerosol generating substrate may include at least one aerosol forming body. The aerosol generating article may have a downstream section located downstream of the rod of the aerosol generating substrate. The aerosol generating article may include at least a wrapper surrounding the rod of the aerosol generating substrate. The density of the aerosol generating substrate may be greater than about 300 milligrams per cubic centimeter. The wrapper may contain a flame-retardant composition comprising one or more flame-retardant compounds.

[0010] 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 downstream section located downstream of the rod of the aerosol generating substrate, and a wrapper surrounding at least the rod of the aerosol generating substrate. The density of the aerosol generating substrate is more than about 300 milligrams per cubic centimeter. Furthermore, the wrapper comprises a flame-retardant composition containing one or more flame-retardant compounds.

[0011] The disclosure further relates to a method for manufacturing an aerosol-generating article for generating an inhalable aerosol upon heating. The method may include the step of providing a continuous rod of aerosol-generating substrate having a density of more than about 300 milligrams per cubic centimeter. The method may further include the step of surrounding the continuous rod of aerosol-generating substrate with a wrapper containing a flame-retardant composition. The method may also include the additional step of cutting the surrounded continuous rod into separate rods, each separate rod being surrounded by a portion of the wrapper containing the flame-retardant composition.

[0012] The present invention further provides a method for manufacturing an aerosol generating article for generating an inhalable aerosol upon heating, the method comprising providing a continuous rod of aerosol generating substrate, wherein the density of the aerosol generating substrate is greater than about 300 milligrams per cubic centimeter, surrounding the continuous rod of aerosol generating substrate with a wrapper containing a flame retardant composition, and cutting the surrounded continuous rod into separate rods, each separate rod being surrounded by a portion of the wrapper containing the flame retardant composition.

[0013] The disclosure also relates to an aerosol generating system comprising electrically operated aerosol generating devices and aerosol generating articles, as described above. The aerosol generating device may include means for heating a rod of aerosol generating substrate to a temperature sufficient to generate aerosols from the aerosol generating substrate.

[0014] According to the present invention, an aerosol generating system is further provided comprising the electrically operated aerosol generating device and aerosol generating article described above, the aerosol generating device including means for heating a rod of an aerosol generating substrate to a temperature sufficient to generate an aerosol from the aerosol generating substrate.

[0015] As briefly described above, the present invention provides an aerosol generating article for generating an inhalable aerosol upon heating, the article comprising a rod of an aerosol generating substrate and a downstream section located downstream of the rod of the aerosol generating substrate. More specifically, the present invention provides an aerosol generating article for generating an inhalable aerosol upon heating at a temperature of about 100 degrees Celsius to about 800 degrees Celsius, preferably about 150 degrees Celsius to about 500 degrees Celsius, more preferably about 200 degrees Celsius to about 300 degrees Celsius.

[0016] These temperatures are significantly lower than those reached in conventional cigarettes during the combustion of the tobacco-containing substrate, and even more significantly lower than the temperatures reached by commercially available cigarette lighters, which range from approximately 1000 to 2000 degrees Celsius and even higher.

[0017] Furthermore, the aerosol-generating article includes a rod of aerosol-generating substrate, or a wrapper enclosing both the rod and the downstream section of the aerosol-generating substrate. In contrast to existing articles, the aerosol-generating substrate has a density of more than approximately 300 milligrams per cubic centimeter, and the wrapper contains a flame-retardant composition.

[0018] The inventors have found that by surrounding an aerosol-generating substrate with a wrapper containing a flame-retardant composition, i.e., a wrapper containing one or more flame-retardant compounds, it is advantageously possible to prevent charring or carbonization of the wrapper and the underlying aerosol-generating substrate during use due to heating. In other words, it is advantageously possible to substantially prevent combustion and thermal decomposition of the components of the aerosol-generating article according to the present invention.

[0019] In the aerosol-generating article according to the present invention, this is preferably achieved without requiring an additional layer of metal foil or other heat-shielding material to be included in the aerosol-generating article. This simplifies the manufacturing process and therefore can reduce manufacturing costs. Furthermore, when used aerosol-generating articles are discarded, it is not necessary to separate and recover valuable recyclable materials such as aluminum foil, making disposal of the aerosol-generating article according to the present invention easier. In addition, the inventors have found that by surrounding the aerosol-generating substrate with the aforementioned wrapper, when the aerosol-generating substrate is exposed to temperatures in the range of approximately 100 to 800 degrees Celsius during use, the aerosol-generating article discolors significantly and the surface of the wrapper turns dark brown or black. Therefore, consumers can immediately know whether the aerosol-generating article has been used previously and should be discarded.

[0020] By adjusting the amount of flame-retardant compound in the wrapper (e.g., the amount per square meter of surface area of ​​the treated portion), the degree to which the wrapper surface is treated with the flame-retardant composition, and the formulation of the flame-retardant composition (i.e., the properties of the flame-retardant compound), it is possible to advantageously improve the flame-retardant properties of the wrapper and the entire aerosol-generating article.

[0021] Accordingly, the present invention provides an improved aerosol-generating article that can substantially prevent charring and carbonization of the aerosol-generating substrate and wrapper during use. This is because, by providing one or more flame-retardant compounds on or inside the wrapper, or both, the heat supplied to the article to generate aerosols can be substantially prevented from causing thermal decomposition or combustion of the wrapper substrate.

[0022] An advantage of the aerosol-generating article according to the present invention is that, unlike existing aerosol-generating articles, it does not need to contain a metal foil layer, making disposal easier and reducing the environmental impact.

[0023] Furthermore, the aerosol generating article according to the present invention has the additional benefit that it can only be correctly used as intended, i.e., in combination with an apparatus adapted to heat the aerosol generating substrate. In fact, unlike conventional cigarettes, the aerosol generating article according to the present invention is essentially non-ignitable and cannot sustain combustion like a conventional cigarette.

[0024] According to the present invention, there is provided an aerosol generating article for generating an inhalable aerosol upon heating.

[0025] The term "aerosol generating article" is used herein to mean an article in which an aerosol generating substrate is heated to generate an inhalable aerosol and deliver it to a consumer. The term "aerosol generating substrate" as used herein means a substrate having the ability to release volatile compounds upon heating to generate an aerosol.

[0026] Conventional cigarettes are ignited when a user applies a flame to one end of the cigarette and draws air through the other end. The localized heat provided by 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 a heated aerosol generating article, the aerosol is generated by heating a flavor generating substrate (such as tobacco). Known heated aerosol generating articles include, for example, electrically heated aerosol generating articles and aerosol generating articles in which the aerosol is generated by the transfer of heat from a combustible fuel element or heat source to an aerosol forming material physically separated therefrom. For example, the aerosol generating article according to the present invention has a specific application in an aerosol generating system comprising an electrically heated aerosol generating device having an internal heater blade adapted to be inserted into a rod of the aerosol generating substrate. This type of aerosol generating article is described in the prior art, for example, EP0822670.

[0027] As used herein, the term "aerosol generating device" refers to a device comprising a heating element that interacts with an aerosol generating substrate of an aerosol generating article to generate an aerosol.

[0028] As used herein in connection with the present invention, the term "rod" is used to denote a generally cylindrical element having a substantially circular, oval or elliptical cross-section.

[0029] As used herein, the term "longitudinal direction" refers to the direction corresponding to the major longitudinal axis of the aerosol generating article, which extends 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 portion of an element) of the aerosol generating article with respect to the direction in which the aerosol is conveyed through the aerosol generating article during use.

[0030] 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 a "cross-section" of the aerosol generating article or a component of the aerosol generating article refers to a cross-sectional plane, unless otherwise specified.

[0031] The term "length" means the dimension of a component of the aerosol generating article in the longitudinal direction. For example, it may be used to mean the dimension of a rod or an elongate tubular element in the longitudinal direction. <>

[0032] An aerosol generating article according to the present invention comprises a rod of an aerosol generating substrate. Further, the aerosol generating article comprises a downstream section located downstream of the rod of the aerosol generating substrate.

[0033] In the aerosol generating article according to the present invention, at least the rods of the aerosol generating substrate are surrounded by a wrapper. This means that, in the aerosol generating article according to the present invention, the same wrapper surrounding the rods of the aerosol generating substrate may also surround at least a portion of the downstream section of the aerosol generating article provided upstream of the rods of the aerosol generating substrate, or at least a portion of any additional components, or both.

[0034] The aerosol-generating article may have a total length of approximately 35 mm to approximately 100 mm.

[0035] 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.

[0036] In some embodiments, the total length of the aerosol generating article according to the present invention is preferably 80 millimeters or less. More preferably, the total length of the aerosol generating article according to the present invention is preferably 70 millimeters or less. Even more preferably, the total length of the aerosol generating article according to the present invention is preferably 60 millimeters or less. Most preferably, the total length of the aerosol generating article according to the present invention is preferably 50 millimeters or less.

[0037] In a preferred embodiment, the total length of the aerosol-generating article is 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 another embodiment, 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 yet another embodiment, 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.

[0038] In other embodiments, the total length of the aerosol generating article according to the present invention is preferably at least about 40 millimeters, more preferably about 50 millimeters, and even more preferably about 60 millimeters. In these embodiments, the total length of the aerosol generating article is preferably about 95 millimeters or less, more preferably about 90 millimeters or less, even more preferably about 85 millimeters or less, and most preferably about 80 millimeters or less.

[0039] In a preferred embodiment, the total length of the aerosol generating article is about 40 mm to about 95 mm, preferably about 40 mm to about 90 mm, more preferably about 40 mm to about 85 mm, and even more preferably about 40 mm to about 80 mm. In another embodiment, the total length of the aerosol generating article is about 50 mm to about 95 mm, preferably about 50 mm to about 90 mm, more preferably about 50 mm to about 85 mm, and even more preferably about 50 mm to about 80 mm. In yet another embodiment, the total length of the aerosol generating article is about 60 mm to about 95 mm, preferably about 60 mm to about 90 mm, more preferably about 60 mm to about 85 mm, and even more preferably about 60 mm to about 80 mm. In further embodiments, the total length of the aerosol-generating article is approximately 70 mm to approximately 95 mm, preferably approximately 70 mm to approximately 90 mm, more preferably approximately 70 mm to approximately 85 mm, and even more preferably approximately 70 mm to approximately 80 mm. In an exemplary embodiment, the total length of the aerosol-generating article is approximately 75 mm.

[0040] The aerosol generating article according to the present invention may have an outer diameter of at least 4 millimeters. Preferably, the aerosol generating article has an outer diameter of at least 5 millimeters. More preferably, the aerosol generating article has an outer diameter of at least 6 millimeters. Even more preferably, the aerosol generating article has an outer diameter of at least 7 millimeters.

[0041] 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.

[0042] In some embodiments, the aerosol-generating article has an outer diameter of about 4 mm to about 12 mm, preferably about 5 mm to about 12 mm, more preferably about 6 mm to about 12 mm, and even more preferably about 7 mm to about 12 mm. In other embodiments, the aerosol-generating article has an outer diameter of about 4 mm to about 10 mm, preferably about 5 mm to about 10 mm, more preferably about 6 mm to about 10 mm, and even more preferably about 7 mm to about 10 mm. In further embodiments, the aerosol-generating article has an outer diameter of about 4 mm to about 8 mm, preferably about 5 mm to about 8 mm, more preferably about 6 mm to about 8 mm, and even more preferably about 7 mm to about 8 mm.

[0043] The rod of the aerosol generating substrate may have a length of approximately 5 mm to approximately 100 mm.

[0044] In some embodiments, the rod of the aerosol generating substrate preferably has a length of at least about 6 millimeters, and more preferably at least about 7 millimeters. In these embodiments, the rod of the aerosol generating substrate may have a length of less than about 90 millimeters, preferably less than about 70 millimeters, more preferably less than about 65 millimeters, more preferably less than about 50 millimeters, and most preferably less than 40 millimeters. In a particularly preferred embodiment, the rod of the aerosol generating substrate has a length of less than about 35 millimeters, more preferably less than 25 millimeters, and even more preferably less than about 20 millimeters. In one embodiment, the rod of the aerosol generating substrate may have a length of about 10 millimeters. In a preferred embodiment, the rod of the aerosol generating substrate has a length of about 12 millimeters. This may be combined with the total length of the aerosol generating article, which is about 45 millimeters.

[0045] In other embodiments, the rod of the aerosol generating substrate preferably has a length of at least about 10 millimeters, more preferably at least about 20 millimeters, and even more preferably at least about 30 millimeters. In these embodiments, the length of the rod of the aerosol generating substrate is preferably about 60 millimeters or less, more preferably about 50 millimeters or less, and even more preferably about 40 millimeters or less.

[0046] In a preferred embodiment, the length of the rod of the aerosol generating substrate is about 10 mm to about 60 mm, preferably about 20 mm to about 60 mm, and more preferably about 30 mm to about 60 mm. In another embodiment, the length of the rod of the aerosol generating substrate is about 10 mm to about 50 mm, preferably about 20 mm to about 50 mm, and more preferably about 30 mm to about 50 mm. In yet another embodiment, the length of the rod of the aerosol generating substrate is about 10 mm to about 40 mm, preferably about 20 mm to about 40 mm, and more preferably about 40 mm to about 60 mm. In an exemplary embodiment, the length of the rod of the aerosol generating substrate is about 35 mm. This may be combined with the total length of the aerosol generating article, which is about 75 mm.

[0047] The rod of the aerosol generating substrate preferably has a substantially uniform cross-section along its length. It is particularly preferable that the rod of the aerosol generating substrate has a substantially circular cross-section.

[0048] According to the present invention, the density of the aerosol-generating substrate is more than approximately 300 milligrams per cubic centimeter. As used herein, with reference to the aerosol-generating substrate of an aerosol-generating article according to the present invention, the term "density" means the "apparent density" or "volume density" of the substrate, which is equal to the total mass of the body of the aerosol-generating substrate in a given volume (which is the mass of homogenized plant material, an aerosol-forming body, or the mass of a given volume of gel composition) divided by the given volume of the rod of the aerosol-generating substrate.

[0049] Thus, for example, the density of the aerosol-generating substrate determines the mass of a given volume of homogenized tobacco material and the packaging efficiency of a given surface area of ​​the homogenized tobacco material. The density of homogenized tobacco material is usually determined by the type of process used in its manufacture. Numerous reconstitution processes for producing homogenized tobacco material are known in the industry. These include, but are not limited to, the papermaking process of the type described in U.S. Patent No. A-5,724,998, the casting process of the type described in U.S. Patent No. A-5,724,998, the soft mass reconstitution process of the type described in U.S. Patent No. A-3,894,544, and the extrusion process of the type described in British Patent No. A-983,928.

[0050] Generally, the density of homogenized tobacco material produced by extrusion molding and soft block reconstruction processes is greater than that of homogenized tobacco material produced by casting processes. The density of homogenized tobacco material produced by extrusion molding may be greater than that of homogenized tobacco material produced by soft block reconstruction processes.

[0051] For example, the density of the aerosol-generating substrate is at least about 310 milligrams per cubic centimeter, or at least about 320 milligrams per cubic centimeter, or at least about 330 milligrams per cubic centimeter.

[0052] In some embodiments, the density of the aerosol generating substrate is preferably at least about 350 milligrams per cubic centimeter. More preferably, the density of the aerosol generating substrate is at least about 400 milligrams per cubic centimeter. Even more preferably, the density of the aerosol generating substrate is at least about 450 milligrams per cubic centimeter. In particularly preferred embodiments, the density of the aerosol generating substrate is at least about 500 milligrams per cubic centimeter. Preferably, the density of the aerosol generating substrate is about 1000 milligrams or less per cubic centimeter, more preferably about 900 milligrams or less per cubic centimeter, and even more preferably about 800 milligrams or less per cubic centimeter. As an example, the density of the aerosol generating substrate may be about 350 milligrams to about 1000 milligrams per cubic centimeter, preferably about 400 milligrams to about 1000 milligrams per cubic centimeter, more preferably about 450 milligrams to about 1000 milligrams per cubic centimeter, and even more preferably about 500 milligrams to about 1000 milligrams per cubic centimeter. As another example, the density of the aerosol generating substrate may be about 350 milligrams to about 900 milligrams per cubic centimeter, preferably about 400 milligrams to about 900 milligrams per cubic centimeter, more preferably about 450 milligrams to about 900 milligrams per cubic centimeter, and even more preferably about 500 milligrams to about 900 milligrams per cubic centimeter.As a further example, the density of the aerosol-generating substrate may be about 350 milligrams to about 800 milligrams per cubic centimeter, preferably about 400 milligrams to about 800 milligrams per cubic centimeter, more preferably about 450 milligrams to about 800 milligrams per cubic centimeter, and even more preferably about 500 milligrams to about 800 milligrams per cubic centimeter.

[0053] In other embodiments, the density of the aerosol generating substrate is at least about 600 milligrams per cubic centimeter, preferably at least about 700 milligrams per cubic centimeter, more preferably at least about 800 milligrams per cubic centimeter, and even more preferably at least about 900 milligrams per cubic centimeter. In some particularly preferred embodiments, the density of the aerosol generating substrate is at least about 1 gram per cubic centimeter, preferably at least about 1.1 grams per cubic centimeter, more preferably at least about 1.2 grams per cubic centimeter, and even more preferably at least about 1.3 grams per cubic centimeter. Preferably, the density of the aerosol generating substrate is about 2.0 grams or less per cubic centimeter, more preferably about 1.9 grams or less per cubic centimeter, and even more preferably about 1.8 grams or less per cubic centimeter. In preferred embodiments, the density of the aerosol generating substrate is about 1.7 grams or less per cubic centimeter, more preferably about 1.6 grams or less per cubic centimeter, and even more preferably about 1.5 grams or less per cubic centimeter.

[0054] As an example, the density of the aerosol generating substrate is about 1 gram to about 1.7 grams per cubic centimeter, preferably about 1.1 grams to about 1.7 grams per cubic centimeter, more preferably about 1.2 grams to about 1.7 grams per cubic centimeter, and even more preferably about 1.3 grams to about 1.7 grams per cubic centimeter. As another example, the density of the aerosol generating substrate is about 1 gram to about 1.6 grams per cubic centimeter, preferably about 1.1 grams to about 1.6 grams per cubic centimeter, more preferably about 1.2 grams to about 1.6 grams per cubic centimeter, and even more preferably about 1.3 grams to about 1.6 grams per cubic centimeter. As a further example, the density of the aerosol-generating substrate is about 1 gram to about 1.5 grams per cubic centimeter, preferably about 1.1 grams to about 1.5 grams per cubic centimeter, more preferably about 1.2 grams to about 1.5 grams per cubic centimeter, and even more preferably about 1.3 grams to about 1.5 grams per cubic centimeter.

[0055] The aerosol generating substrate may be a solid aerosol generating substrate.

[0056] In a particular preferred embodiment, the aerosol-generating substrate comprises homogenized plant material, preferably homogenized tobacco material.

[0057] 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, one or more tobacco leaf laminas and tobacco leaf stems, which are obtained by grinding, crushing, or pulverizing tobacco material particles. The homogenized plant material may be produced by casting, extrusion, papermaking processes, or any other suitable process known in the art.

[0058] 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 substantially greater than its thickness.

[0059] Alternatively, or additionally, the homogenized plant material may be in the form of multiple pellets or granules.

[0060] 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.

[0061] 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.

[0062] 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.

[0063] Each of the sheets described herein is individually approximately 100 g / m² 2 ~about 300g / m 2 It may have a basis weight of [a certain amount].

[0064] Each of the sheets described herein contains approximately 0.3 g / cm² of material. 3 ~Approx. 1.3g / cm3 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].

[0065] 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.

[0066] 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.

[0067] 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.

[0068] 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.

[0069] 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 about 2 millimeters, or less. The length of the strands may be longer than about 5 millimeters, or about 5 millimeters to about 15 millimeters, or about 8 millimeters to 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 may break, especially during transition. In such cases, the length of some strands may be shorter than the length of the plugs.

[0070] It is preferable that the strands are aligned with the longitudinal axis and extend substantially along the length of the aerosol-generating substrate in the longitudinal direction. Therefore, it is preferable that the strands are aligned substantially parallel to one another.

[0071] 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.

[0072] 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.

[0073] In certain embodiments of the present invention, the homogenized plant material is a homogenized tobacco material containing tobacco particles. The 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 least about 50 weight percent on a dry weight basis, more preferably at least about 70 weight percent on a dry weight basis, and most preferably at least about 90 weight percent on a dry weight basis.

[0074] 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” includes 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, separated 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.

[0075] Tobacco particles may be prepared from one or more varieties of tobacco plants. Any type of tobacco may be used in the blend. Examples of types of tobacco materials that may be used include, but are not limited to, sun-dried tobacco, fire-dried tobacco, Burley tobacco, Maryland tobacco, Oriental tobacco, Virginia tobacco, and other specialty tobaccos.

[0076] 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.

[0077] Burley tobacco plays an important role in many tobacco blends. It possesses a distinctive flavor and aroma, and has the ability to absorb a large amount of casing.

[0078] 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.

[0079] 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.

[0080] 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.

[0081] In certain other embodiments of the present invention, the homogenized plant material includes tobacco particles in combination with non-tobacco plant-flavored particles. Preferably, the non-tobacco plant-flavored particles are selected from one or more of ginger 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.

[0082] 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.

[0083] As an alternative method for including tobacco particles in the homogenized plant material of the aerosol-generating substrate according to the present invention, or in addition thereto, the homogenized plant material may include cannabis particles. The term "cannabis particles" refers to particles of cannabis plants such as Cannabis sativa, Cannabis indica, and Cannabis ruderalis.

[0084] 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.

[0085] 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.

[0086] 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.

[0087] 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, palm 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 Revel A, as well as combinations thereof.

[0088] Alternatively, or additionally, the homogenized plant material may further contain a pH adjuster.

[0089] 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, as well as 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.

[0090] 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.

[0091] 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).

[0092] 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.

[0093] 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.

[0094] In other embodiments, 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.

[0095] In other embodiments, 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.

[0096] 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.

[0097] As used herein, the term “additional cellulose” encompasses any cellulose material incorporated into the homogenized plant material, which is not derived 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 is typically derived 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.

[0098] The additional cellulose may include cellulose powder, cellulose fibers, or a combination thereof.

[0099] The aerosol-forming material can act as a wetting agent in the aerosol-generating substrate.

[0100] In certain 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.

[0101] 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.

[0102] 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.

[0103] 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 the range 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 / low total particulate matter (TPM) aerosol to the consumer, preferably in a continuous manner.

[0104] 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.

[0105] 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.

[0106] The term “alkaloid compound” refers to any one class of naturally occurring organic compounds containing one or more basic nitrogen atoms. Generally, alkaloids contain at least one nitrogen atom in an amine-type structure. This nitrogen atom or another nitrogen atom within 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.

[0107] The gel composition preferably contains an alkaloid compound selected from the group consisting of nicotine, anatabine, and combinations thereof.

[0108] Preferably, the gel composition contains nicotine.

[0109] The term "nicotine" refers to nicotine and nicotine derivatives (e.g., free base nicotine, nicotine salts, and similar substances).

[0110] 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.

[0111] 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.

[0112] The gel composition may preferably contain a cannabinoid compound selected from the group consisting of cannabidiol (CBD), THC (tetrahydrocannabinol), and combinations thereof.

[0113] The gel may preferably contain cannabidiol (CBD).

[0114] The gel composition may contain nicotine and cannabidiol (CBD).

[0115] The gel composition may contain nicotine, cannabidiol (CBD), and THC (tetrahydrocannabinol).

[0116] 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.

[0117] 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.

[0118] The gel composition includes an aerosol-forming body. Ideally, the aerosol-forming body is substantially resistant to thermal degradation at the operating temperature of the associated aerosol generator. Suitable aerosol-forming bodies 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 body is preferably glycerol.

[0119] 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.

[0120] 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.

[0121] 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.

[0122] 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 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 ionic-linked gelling agents.

[0123] The gelling agent may contain one or more biopolymers. The biopolymers may be formed from polysaccharides.

[0124] 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.

[0125] 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.

[0126] 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.

[0127] 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.

[0128] 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.

[0129] 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.

[0130] 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.

[0131] 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.

[0132] 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.

[0133] 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.

[0134] 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.

[0135] 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.

[0136] 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.

[0137] 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.

[0138] 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.

[0139] 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.

[0140] 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.

[0141] 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.

[0142] 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.

[0143] The gel composition may further contain a thickening agent. A thickening agent combined with a hydrogen-bonding crosslinking gelling agent, surprisingly, appears to support the solid culture medium and maintain the gel composition even when it contains high levels of glycerol.

[0144] 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 glycerol 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 glycerol 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 the viscosity by at least 2 times, at least 5 times, at least 10 times, or at least 100 times compared to before addition, causing the mixture to remain in a fluid state or stay fluid.

[0145] 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.

[0146] 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.

[0147] 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.

[0148] 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.

[0149] 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.

[0150] 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.

[0151] 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.

[0152] 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.

[0153] 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.

[0154] 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.

[0155] 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.

[0156] 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.

[0157] 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.

[0158] 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.

[0159] 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.

[0160] 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.

[0161] 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.

[0162] 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.

[0163] Preferably, the aerosol generating substrate contains about 150 mg to about 350 mg of gel composition.

[0164] Preferably, the aerosol generating substrate includes a porous medium loaded with a gel composition. The advantage of the porous medium loaded with the gel composition is that the gel composition is retained within the porous medium, which can assist 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.

[0165] The porous medium can be any suitable porous material capable of holding or retaining the gel composition. Ideally, the porous medium can allow the gel composition to move within it. In certain embodiments, the porous medium includes natural materials, synthetic or semi-synthetic materials, or combinations thereof. In certain embodiments, the porous medium includes sheet materials, foams, or fibers, such as loose fibers, or combinations thereof. In certain embodiments, the porous medium includes woven fabrics, nonwoven fabrics, or extruded materials, or combinations thereof. Preferably, the porous medium includes cotton, paper, viscose, PLA, or cellulose acetate, or combinations thereof. Preferably, the porous medium includes sheet materials, such as cotton or cellulose acetate. In a particularly preferred embodiment, the porous medium includes a sheet made from cotton fibers.

[0166] 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 a shredded porous medium. The crimping or shredding process may be performed before or after loading the gel composition.

[0167] The crimping of sheet materials has the advantage of improving the structure and creating passages through it. These passages in the crimped sheet material facilitate gel loading, gel retention, and fluid passage through the crimped material. Therefore, there are advantages to using crimped sheet materials as porous media.

[0168] Shredding provides a high surface area-to-volume ratio to the medium, allowing it to easily absorb the gel.

[0169] 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 gels. The sheet material can assist in the introduction of activators into tubular elements containing gels. The sheet material may help in stabilizing the structure of tubular elements containing gels. The sheet material can assist in the transport or storage of gels. 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.

[0170] 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.

[0171] 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.

[0172] The porous medium loaded with the gel composition is preferably provided within a tubular element that forms part of an aerosol-generating article. The term “tubular element” is used to describe a component suitable for use in an aerosol-generating article. Ideally, the tubular element has a longitudinal length greater than its width, but this is not necessarily required, as it may be part of a multi-component item where its longitudinal length is ideally greater 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, or rectangular polygonal, or irregular cross-section.

[0173] 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 helps not to lose structure, rigidity, or stiffness. This can also help prevent leakage of gel or liquid, especially when a gel is used in a fluid structure.

[0174] In some embodiments, the rod of the aerosol generating substrate further comprises a susceptor element disposed within the aerosol generating substrate. In practice, in some embodiments of the aerosol generating article according to the present invention, the susceptor element, for example, an elongated susceptor, is substantially disposed on the rod of the aerosol generating substrate so that the susceptor element is in thermal contact with the aerosol generating substrate.

[0175] As used herein in relation to the present invention, the term "susceptor" refers to a material capable of converting electromagnetic energy into heat. When located in a fluctuating electromagnetic field, induced eddy currents in the susceptor cause heating of the susceptor. The elongated susceptor is positioned in thermal contact with an aerosol-generating substrate, and the aerosol-generating substrate is heated by the susceptor.

[0176] The susceptor element is preferably in the form of an elongated susceptor. When used to describe a susceptor, the term “elongated” means that the susceptor has a length dimension that is greater than its width dimension or thickness dimension, for example, a length dimension greater than twice its width dimension or thickness dimension.

[0177] The elongated susceptor is preferably positioned substantially longitudinally within the rod. This means that the length dimension of the elongated susceptor is aligned substantially parallel to the longitudinal direction of the rod, for example, within ±10 degrees of parallel to the longitudinal direction of the rod. In a preferred embodiment, the elongated susceptor may be positioned radially centrally within the rod and extend along the longitudinal axis of the rod.

[0178] Preferably, the elongated susceptor extends entirely to the downstream end of the rod of the aerosol-generating article. In some embodiments, the susceptor may extend entirely to the upstream end of the rod of the aerosol-generating article. In a particularly preferred embodiment, the susceptor 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.

[0179] The susceptor is preferably in the form of a pin, rod, strip, or blade.

[0180] The susceptor 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.

[0181] The ratio between the length of the susceptor and the total length of the aerosol-generating article can be approximately 0.2 to 0.35.

[0182] In some embodiments, the ratio of the susceptor length to the total length of the aerosol-generating article is at least about 0.22, more preferably at least about 0.24, and even more preferably at least about 0.26. The ratio of the susceptor length to the total length of the aerosol-generating article is preferably less than about 0.34, more preferably less than about 0.32, and even more preferably less than about 0.3. In other embodiments, the ratio of the susceptor length to the total length of the aerosol-generating article 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 further embodiments, the ratio of the susceptor length to the total length of the aerosol-generating article 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 between the length of the susceptor and the total length of the aerosol-generating article 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.

[0183] In a particularly preferred embodiment, the ratio between the length of the susceptor and the total length of the aerosol-generating article is approximately 0.27.

[0184] The susceptor preferably has a width of about 1 mm to about 5 mm.

[0185] The susceptor can generally have a thickness of about 0.01 mm to about 2 mm, for example, about 0.5 mm to about 2 mm. In some embodiments, the susceptor preferably has a thickness of about 10 micrometers to about 500 micrometers, more preferably about 10 micrometers to about 100 micrometers.

[0186] If the susceptor 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.

[0187] If the susceptor 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 in the form of a blade strip may have a width of about 4 mm.

[0188] If the susceptor has the form of a strip or blade, the strip or blade preferably has a rectangular shape and 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 in the form of a blade strip may have a thickness of about 0.07 mm.

[0189] In a preferred embodiment, the elongated susceptor is provided in the form of a strip or blade, preferably having a rectangular shape and a thickness of about 55 micrometers to about 65 micrometers.

[0190] More preferably, the elongated susceptor has a thickness of about 57 micrometers to about 63 micrometers. Even more preferably, the elongated susceptor has a thickness of about 58 micrometers to about 62 micrometers. In a particularly preferred embodiment, the elongated susceptor has a thickness of about 60 micrometers.

[0191] While not wishing to be constrained by theory, the inventors believe that, as a whole, the selection of a given susceptor thickness is also influenced by constraints set by the selected length and width of the susceptor, as well as by constraints set by the geometric shape and dimensions of the rod of the aerosol generating substrate. As an example, the length of the susceptor is preferably selected to match the length of the rod of the aerosol generating substrate. The width of the susceptor should preferably be selected so as to prevent displacement of the susceptor within the substrate, while also allowing for easy insertion during manufacturing.

[0192] The inventors have found that susceptors having a thickness within the aforementioned range are advantageous in aerosol-generating articles provided to inductively supply heat during use, as they generate and distribute heat in a particularly effective and efficient manner throughout the aerosol-generating substrate. While not wishing to be bound by theory, the inventors believe that such susceptors are adapted to provide optimal heat generation and heat transfer due to their surface area and inductive force. In contrast, thinner susceptors are too easily deformed and may not maintain the desired shape and orientation within the rod of the aerosol-generating substrate during the manufacturing of the aerosol-generating article, resulting in less homogeneous and finely tuned heat distribution during use. At the same time, thicker susceptors may be more difficult to cut to precise and consistent lengths, which may also affect how accurately the susceptors are provided aligned longitudinally within the rod of the aerosol-generating substrate, and thus the homogeneity of the heat distribution within the rod. These beneficial effects are particularly noticeable when the susceptor extends fully to the downstream end of the rod of the aerosol-generating article. This is thought to be because the downstream RTD can be essentially minimized because there is no aerosol-generating substrate in the rod located downstream of the susceptor, which could contribute to the RTD. This is achieved particularly effectively in embodiments in which the aerosol-generating article includes a downstream section containing a hollow intermediate section. One such hollow intermediate section does not substantially contribute to the overall RTD of the aerosol-generating article and does not directly contact the downstream end of the susceptor.

[0193] While not wishing to be bound by theory, the inventors believe that the downstream portion of the aerosol generating substrate rod can, to some extent, act as a filter for the upstream portion of the aerosol generating substrate rod. Therefore, the inventors believe it is desirable that the downstream portion of the aerosol generating substrate rod can also be heated uniformly, thereby actively counteracting any filtering effect that could potentially interfere with the release of volatile aerosol species, contribute to the overall generation and delivery of aerosols, and hinder the delivery of aerosols to consumers, as volatile aerosol species are released throughout the aerosol generating substrate.

[0194] The elongated susceptor is preferably the same length as or shorter than the aerosol-generating substrate.

[0195] The susceptor may be formed from any material that can be inductively heated to a temperature sufficient to generate an aerosol from the aerosol-generating substrate. Preferred susceptors include metals or carbon.

[0196] A preferred susceptor may contain or consist of a ferromagnetic material (e.g., ferromagnetic alloy, ferrite iron, or ferromagnetic steel or ferromagnetic stainless steel). A preferred susceptor may also be aluminum or contain aluminum. A preferred susceptor may be formed from 400 series stainless steel, for example, grade 410, or 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.

[0197] Thus, the parameters of the susceptor, such as the type of material, length, width, and thickness, may all be modified to provide desirable power dissipation within a known electromagnetic field. A preferred susceptor may be heated to a temperature above 250 degrees Celsius.

[0198] A suitable susceptor may include a nonmetallic core having a metal layer disposed on top of a nonmetallic core, for example, a metal track formed on the surface of a ceramic core. The susceptor may have a protective outer layer enclosing the susceptor, for example, a protective ceramic layer or a protective glass layer. The susceptor may also include a protective coating formed of glass, ceramic, or an inert metal formed on the core of the susceptor material.

[0199] The susceptor is positioned in thermal contact with the aerosol-generating substrate. As the temperature of the susceptor rises, the aerosol-generating substrate is heated, and an aerosol is formed. Preferably, the susceptor is positioned, for example, within the aerosol-generating substrate, in direct physical contact with the aerosol-generating substrate.

[0200] The susceptor may be a multi-material susceptor and may include a first susceptor material and a second susceptor material. The first susceptor material is arranged in physical contact with the second susceptor material. The second susceptor material preferably has a Curie temperature lower than 500 degrees Celsius. The first susceptor material is preferably used primarily to heat the susceptor when it is placed in a fluctuating electromagnetic field. Any suitable material may be used. For example, the first susceptor material may be aluminum or an iron-based material such as stainless steel. The second susceptor material is preferably used primarily to indicate when the susceptor has reached a specific temperature (the Curie temperature of the second susceptor material). The Curie temperature of the second susceptor material can be used to regulate the overall temperature of the susceptor during operation. Therefore, the Curie temperature of the second susceptor material should be below the ignition point of the aerosol generating substrate. Suitable materials for the second susceptor material may include nickel and certain nickel alloys.

[0201] The heating of the aerosol generating substrate and the temperature control of its heating can be separated by providing a susceptor having at least first and second susceptor materials, a second susceptor material having a Curie temperature and a first susceptor material not having a Curie temperature, or by providing first and second susceptor materials having different first and second Curie temperatures. The first susceptor 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 material exceeds any maximum temperature to which the susceptor 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 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 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 material may be selected such that, when heated by a susceptor with a temperature equal to the second Curie temperature, the overall average temperature of the aerosol-generating substrate does not exceed 240 degrees Celsius.

[0202] As briefly described above, in the aerosol-generating article according to the present invention, at least the wrapper surrounding the rod of the aerosol-generating substrate contains a flame-retardant composition. In practice, at least the wrapper surrounding the rod of the aerosol-generating substrate includes a wrapping substrate, and the flame-retardant composition is applied to the wrapping substrate, or the wrapping substrate is impregnated with the flame-retardant composition, or both.

[0203] As used herein, the term "flame-retardant composition" means a composition comprising one or more flame-retardant compounds.

[0204] The term “flame retardant compound” is used herein to describe compounds that, when added to or otherwise incorporated into a substrate such as paper or plastic compounds, provide the substrate with varying degrees of flammability protection. In practice, flame retardant compounds may be activated by the presence of an ignition source and are adapted to prevent or delay the further development of ignition by various different physical and chemical mechanisms.

[0205] A flame-retardant composition may typically further include one or more non-flammable compounds, i.e., one or more compounds that do not actively contribute to providing flammability protection to a substrate, but are used to facilitate the application of the flame-retardant compound onto or within the wrapper, or both, such as solvents, excipients, or fillers.

[0206] Some of the non-flammable compounds in a flame-retardant composition, such as solvents, are volatile and can evaporate from the wrapper as it dries after the flame-retardant composition has been applied to, in, or both of, the wrapping substrate. Therefore, although these non-flammable compounds form part of the formulation of the flame-retardant composition, they are no longer present or can only be detected in trace amounts in the wrapper of the aerosol-generating article according to the present invention.

[0207] To incorporate a flame-retardant composition into a paper-based or polymer-based wrapper, the flame-retardant composition may be added to the pulp or polymer mixture during the wrapper manufacturing process, or it may be added to the wrapper at a later stage by an application process based on sizing, spraying, printing, coating, etc. The flame-retardant composition may be applied, for example, as a coating layer to one side or both sides of the wrapper.

[0208] Numerous suitable flame retardant compounds are known. Some flame retardant compounds, such as mineral flame retardants, act primarily as additive flame retardants and do not chemically bond to the surrounding system. Most organic halogen compounds and organophosphate compounds also do not react permanently and adhere to the surrounding environment. Reactive flame retardants, such as certain non-halogenated products, are reactive in that they are incorporated into the surrounding system without losing their flame retardant efficiency. This makes it advantageous that these materials are not released into the environment.

[0209] The wrapping substrate of the wrapper surrounding at least the rod of the aerosol generating substrate may be a paper wrapping substrate or a non-paper wrapping substrate. In a preferred embodiment, the wrapping substrate of the wrapper surrounding the rod of the aerosol generating substrate includes paper. Suitable paper wrapping substrates 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 wraps. Suitable non-paper wrapping substrates 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 and sheets of certain polymer materials. In a particular embodiment, the wrapping substrate may be formed from a laminated material comprising multiple layers.

[0210] As an example, the wrapping substrate may have a basis weight of at least about 20 grams per square meter. Preferably, the wrapping substrate has a basis weight of at least about 25 grams per square meter. More preferably, the wrapping substrate has a basis weight of at least 30 grams per square meter. Even more preferably, the wrapping substrate has a basis weight of at least about 40 grams per square meter, or at least about 50 grams per square meter. In some embodiments, the wrapping substrate has a basis weight of at least about 70 grams per square meter.

[0211] The wrapping substrate may have a basis weight of approximately 220 grams per square meter. Preferably, the wrapping substrate has a basis weight of approximately 200 grams or less per square meter. More preferably, the wrapping substrate has a basis weight of approximately 180 grams or less per square meter. Even more preferably, the wrapping substrate has a basis weight of approximately 160 grams or less per square meter.

[0212] In a preferred embodiment, the wrapping substrate has a basis weight of about 150 grams or less per square meter, preferably about 140 grams or less per square meter, more preferably about 130 grams or less per square meter, and most preferably about 120 grams or less per square meter.

[0213] In some embodiments, the wrapping substrate may have a basis weight of about 30 grams to about 220 grams per square meter, preferably about 40 grams to about 220 grams per square meter, more preferably about 50 grams to about 220 grams per square meter, and even more preferably about 60 grams to about 220 grams per square meter. In other embodiments, the wrapping substrate may have a basis weight of about 30 grams to about 200 grams per square meter, preferably about 40 grams to about 200 grams per square meter, more preferably about 50 grams to about 200 grams per square meter, and even more preferably about 60 grams to about 200 grams per square meter. In further embodiments, the wrapping substrate may have a basis weight of about 30 grams to about 180 grams per square meter, preferably about 40 grams to about 180 grams per square meter, more preferably about 50 grams to about 180 grams per square meter, and even more preferably about 60 grams to about 180 grams per square meter. In yet another embodiment, the wrapping substrate may have a basis weight of about 30 grams to about 160 grams per square meter, preferably about 40 grams to about 160 grams per square meter, more preferably about 50 grams to about 160 grams per square meter, and even more preferably about 60 grams to about 160 grams per square meter.

[0214] In a particularly preferred embodiment, the wrapping substrate may have a basis weight of about 70 grams to about 110 grams per square meter, more preferably about 80 grams to about 110 grams per square meter. In an even more preferred embodiment, the wrapping substrate may have a basis weight of about 70 grams to about 100 grams per square meter, even more preferably about 80 grams to about 100 grams per square meter.

[0215] In other embodiments, the wrapping substrate may have a basis weight of about 20 grams to about 120 grams per square meter, preferably about 25 grams to about 120 grams per square meter, more preferably about 30 grams to about 120 grams per square meter, even more preferably about 40 grams to about 120 grams per square meter, and most preferably about 50 grams to about 120 grams per square meter. In further embodiments, the wrapping substrate may have a basis weight of about 20 grams to about 100 grams per square meter, preferably about 25 grams to about 100 grams per square meter, more preferably about 30 grams to about 100 grams per square meter, even more preferably about 40 grams to about 100 grams per square meter, and most preferably about 50 grams to about 100 grams per square meter. In further embodiments, the wrapping substrate may have a basis weight of about 20 grams to about 80 grams per square meter, preferably about 25 grams to about 80 grams per square meter, more preferably about 30 grams to about 80 grams per square meter, even more preferably about 40 grams to about 80 grams per square meter, and most preferably about 50 grams to about 80 grams per square meter. In alternative embodiments, the wrapping substrate may have a basis weight of about 20 grams to about 70 grams per square meter, preferably about 25 grams to about 70 grams per square meter, more preferably about 30 grams to about 70 grams per square meter, even more preferably about 40 grams to about 70 grams per square meter, and most preferably about 50 grams to about 70 grams per square meter.

[0216] In other embodiments, the wrapping substrate may have a basis weight of about 20 grams to about 50 grams per square meter, preferably about 25 grams to about 50 grams per square meter, more preferably about 30 grams to about 50 grams per square meter, and even more preferably about 40 grams to about 50 grams per square meter.

[0217] The wrapper surrounding at least the rod of the aerosol generating substrate has a total dry basis weight which is the sum of the basis weight of the wrapping substrate and the weight of the flame retardant composition components present on or within the surface of the wrapping substrate, or both. The weight of the flame retardant composition components present on or within the wrapper is the sum of the total weight of the flame retardant compounds and the weight of any residual flame retardant compounds. In the context of this invention, the weight of the flame retardant composition components is also expressed in grams of the components per square meter of the wrapping substrate.

[0218] The ratio of the total weight of the flame retardant compound to the total dry basis weight of the wrapper can be considered an indication of the concentration of the flame retardant compound in the wrapper.

[0219] In the aerosol-generating article according to the present invention, the ratio of the total weight of the flame retardant compound to the total dry basis weight of the wrapper may be at least about 0.02. Preferably, the ratio of the total weight of the flame retardant compound to the total dry basis weight of the wrapper is at least about 0.03. More preferably, the ratio of the total weight of the flame retardant compound to the total dry basis weight of the wrapper is at least about 0.04. Even more preferably, the ratio of the total weight of the flame retardant compound to the total dry basis weight of the wrapper is at least about 0.05.

[0220] The ratio of the total weight of the flame retardant compound to the total dry basis weight of the wrapper is preferably about 0.20 or less. More preferably, the ratio of the total weight of the flame retardant compound to the total dry basis weight of the wrapper is about 0.15 or less. Even more preferably, the ratio of the total weight of the flame retardant compound to the total dry basis weight of the wrapper is about 0.10 or less.

[0221] In some embodiments, the ratio of the total weight of the flame retardant compound to the total dry basis weight of the wrapper may be about 0.02 to about 0.20, preferably about 0.03 to about 0.20, more preferably about 0.04 to about 0.20, and even more preferably about 0.05 to about 0.20. In other embodiments, the ratio of the total weight of the flame retardant compound to the total dry basis weight of the wrapper may be about 0.02 to about 0.15, preferably about 0.03 to about 0.15, more preferably about 0.04 to about 0.15, and even more preferably about 0.05 to about 0.15. In further embodiments, the ratio of the total weight of the flame retardant compound to the total dry basis weight of the wrapper may be about 0.02 to about 0.10, preferably about 0.03 to about 0.10, more preferably about 0.04 to about 0.10, and even more preferably about 0.05 to about 0.10.

[0222] In the aerosol-generating article according to the present invention, the flame-retardant composition is provided to the treated portion of the wrapper. This means that the flame-retardant composition is applied on or in the corresponding portion of the wrapping substrate, or both. Thus, in the treated portion, the wrapper has a total dry basis weight greater than the dry basis weight of the wrapping substrate.

[0223] The treated portion of the wrapper may extend over at least about 10 percent of the outer surface area of ​​the rod of the aerosol generating substrate surrounded by the wrapper. Preferably, the treated portion of the wrapper extends over at least about 20 percent of the outer surface area of ​​the rod of the aerosol generating substrate surrounded by the wrapper. More preferably, the treated portion of the wrapper extends over at least about 40 percent of the outer surface area of ​​the rod of the aerosol generating substrate. Even more preferably, the treated portion of the wrapper extends over at least about 60 percent of the outer surface area of ​​the rod of the aerosol generating substrate. Most preferably, the treated portion of the wrapper extends over at least about 80 percent of the outer surface area of ​​the rod of the aerosol generating substrate.

[0224] In a particularly preferred embodiment, the treated portion of the wrapper extends over at least about 90 percent of the outer surface area of ​​the rod of the aerosol generating substrate. More preferably, the treated portion of the wrapper extends over at least about 95 percent of the outer surface area of ​​the rod of the aerosol generating substrate. Most preferably, the treated portion of the wrapper extends substantially over the entire outer surface area of ​​the rod of the aerosol generating substrate.

[0225] The length of the treated area may be at least about 10 percent of the length of the rod of the aerosol generating substrate. Preferably, the length of the treated area is at least about 20 percent of the length of the rod of the aerosol generating substrate. More preferably, the length of the treated area is at least about 40 percent of the length of the rod of the aerosol generating substrate. Even more preferably, the length of the treated area is at least about 60 percent of the length of the rod of the aerosol generating substrate. Most preferably, the length of the treated area is at least about 80 percent of the length of the rod of the aerosol generating substrate.

[0226] In a particularly preferred embodiment, the length of the treated area is at least about 90 percent of the length of the rod of the aerosol generating substrate. More preferably, the length of the treated area is at least about 95 percent of the length of the rod of the aerosol generating substrate. Most preferably, the length of the treated area is substantially equal to the length of the rod of the aerosol generating substrate.

[0227] At least about 10 grams of the flame retardant composition may be applied to the treated portion per square meter of the surface area of ​​the treated portion. It is preferable to apply at least about 12 grams of the flame retardant composition per square meter of the surface area of ​​the treated portion. It is more preferable to apply at least about 14 grams of the flame retardant composition per square meter of the surface area of ​​the treated portion. It is even more preferable to apply at least about 16 grams of the flame retardant composition per square meter of the surface area of ​​the treated portion. In a particularly preferred embodiment, at least about 18 grams, or at least about 20 grams, of the flame retardant composition is applied to the treated portion per square meter of the surface area of ​​the treated portion.

[0228] It is preferable to apply approximately 35 grams or less of the flame retardant composition to the treated portion per square meter of the surface area of ​​the treated portion. It is more preferable to apply approximately 30 grams or less of the flame retardant composition to the treated portion per square meter of the surface area of ​​the treated portion. It is even more preferable to apply approximately 25 grams or less of the flame retardant composition to the treated portion per square meter of the surface area of ​​the treated portion.

[0229] In some embodiments, about 10 to about 35 grams of the flame retardant composition is applied to the treated portion per square meter of the surface area of ​​the treated portion. It is preferable to apply about 12 to about 35 grams of the flame retardant composition per square meter of the surface area of ​​the treated portion. It is more preferable to apply about 14 to about 35 grams of the flame retardant composition per square meter of the surface area of ​​the treated portion. It is even more preferable to apply about 16 to about 35 grams of the flame retardant composition per square meter of the surface area of ​​the treated portion. In particularly preferred embodiments, about 18 to about 35 grams, or about 20 to about 35 grams, of the flame retardant composition is applied to the treated portion per square meter of the surface area of ​​the treated portion.

[0230] In other embodiments, about 10 to about 30 grams of the flame retardant composition is applied to the treated portion per square meter of the surface area of ​​the treated portion. It is preferable to apply about 12 to about 30 grams of the flame retardant composition per square meter of the surface area of ​​the treated portion. It is more preferable to apply about 14 to about 30 grams of the flame retardant composition per square meter of the surface area of ​​the treated portion. It is even more preferable to apply about 16 to about 30 grams of the flame retardant composition per square meter of the surface area of ​​the treated portion. In particularly preferred embodiments, about 18 to about 30 grams, or about 20 to about 30 grams, of the flame retardant composition is applied to the treated portion per square meter of the surface area of ​​the treated portion.

[0231] In further embodiments, about 10 to about 25 grams of the flame retardant composition is applied to the treated portion per square meter of the surface area of ​​the treated portion. It is preferable to apply about 12 to about 25 grams of the flame retardant composition per square meter of the surface area of ​​the treated portion. It is more preferable to apply about 14 to about 25 grams of the flame retardant composition per square meter of the surface area of ​​the treated portion. It is even more preferable to apply about 16 to about 25 grams of the flame retardant composition per square meter of the surface area of ​​the treated portion. In particularly preferred embodiments, about 18 to about 25 grams, or about 20 to about 25 grams, of the flame retardant composition is applied to the treated portion per square meter of the surface area of ​​the treated portion.

[0232] The treated portion of the wrapper may contain at least about 0.1 grams of flame retardant composition per square meter of surface area of ​​the treated portion. Preferably, the treated portion of the wrapper contains at least about 0.5 grams of flame retardant composition per square meter of surface area of ​​the treated portion. More preferably, the treated portion of the wrapper contains at least about 1.0 gram of flame retardant composition per square meter of surface area of ​​the treated portion. Even more preferably, the treated portion of the wrapper contains at least about 2.0 grams of flame retardant composition per square meter of surface area of ​​the treated portion. In a particularly preferred embodiment, the treated portion of the wrapper contains at least about 3.0 grams of flame retardant compound per square meter of surface area of ​​the treated portion, or at least about 4.0 grams of flame retardant compound per square meter of surface area of ​​the treated portion, or at least about 5.0 grams of flame retardant compound per square meter of surface area of ​​the treated portion.

[0233] The treated portion of the wrapper preferably contains about 12 grams or less of flame retardant composition per square meter of surface area of ​​the treated portion. More preferably, the treated portion of the wrapper contains about 10 grams or less of flame retardant composition per square meter of surface area of ​​the treated portion. Even more preferably, the treated portion of the wrapper contains about 8 grams or less of flame retardant composition per square meter of surface area of ​​the treated portion.

[0234] In some embodiments, the treated portion of the wrapper contains about 0.5 grams to about 12 grams of flame retardant composition per square meter of surface area of ​​the treated portion, preferably about 1.0 gram to about 12 grams of flame retardant composition per square meter of surface area of ​​the treated portion, more preferably about 2.0 grams to about 12 grams of flame retardant composition per square meter of surface area of ​​the treated portion, and even more preferably about 3.0 grams to about 12 grams of flame retardant composition per square meter of surface area of ​​the treated portion.

[0235] In other embodiments, the treated portion of the wrapper contains about 0.5 grams to about 10 grams of flame retardant composition per square meter of surface area of ​​the treated portion, preferably about 1.0 gram to about 10 grams of flame retardant composition per square meter of surface area of ​​the treated portion, more preferably about 2.0 grams to about 10 grams of flame retardant composition per square meter of surface area of ​​the treated portion, and even more preferably about 3.0 grams to about 120 grams of flame retardant composition per square meter of surface area of ​​the treated portion.

[0236] In further embodiments, the treated portion of the wrapper contains about 0.5 grams to about 8 grams of flame retardant composition per square meter of surface area of ​​the treated portion, preferably about 1.0 gram to about 12 grams of flame retardant composition per square meter of surface area of ​​the treated portion, more preferably about 2.0 grams to about 8 grams of flame retardant composition per square meter of surface area of ​​the treated portion, and even more preferably about 3.0 grams to about 8 grams of flame retardant composition per square meter of surface area of ​​the treated portion.

[0237] In the aerosol generating article according to the present invention, the content of the flame retardant compound in the treated portion is preferably such that the aerosol generating article does not ignite when it is heated at 500 degrees Celsius for at least 5 seconds, preferably 30 seconds, using a resistance heating coil. The term "does not ignite" as used herein means, in particular, that combustion of the wrapper surrounding the aerosol generating substrate does not begin and no flame is detected.

[0238] Preferably, the aerosol generating article according to the present invention includes a pre-ignition step using a resistance heating coil, and does not ignite when submitted to the Health Canada Intense Method in a puff regime of 55 ml with a duration of 2 seconds every 30 seconds, with 100 percent of the ventilation zone (if present) on the aerosol generating article blocked. ISO 3308:2000 (Routine analysis of cigarette smoking machines - definitions and standard conditions) provides further details regarding the “smoking” parameter and standard test conditions.

[0239] In some embodiments, the wrapper includes a wrapping substrate, and the layer containing the flame retardant compound is provided on the surface of the wrapping substrate facing the aerosol-generating substrate. In other embodiments, the wrapper includes a wrapping substrate and a layer containing the flame retardant compound provided on the surface of the wrapping substrate facing away from the aerosol-generating substrate. In further embodiments, the wrapper includes a wrapping substrate, and the layer containing the flame retardant compound or compound is provided on both surfaces of the wrapping substrate.

[0240] Numerous suitable flame retardant compounds will be well known to those skilled in the art. In particular, several flame retardant compounds and formulations suitable for treating cellulose materials are known and disclosed and may be used in the manufacture of wrappers for aerosol-generating articles according to the present invention.

[0241] In some embodiments, the flame retardant composition comprises a polymer and a mixed salt based on at least one mono, di, and / or tricarboxylic acid, at least one polyphosphate, pyrophosphate, and / or phosphoric acid, and a hydroxide or alkali or alkaline earth metal salt, wherein the at least one mono, di, and / or tricarboxylic acid and the hydroxide or salt form a carboxylate salt, and the at least one polyphosphate, pyrophosphate, and / or phosphoric acid and the hydroxide or salt form a phosphate salt.

[0242] Preferably, in such embodiments, the flame retardant composition further comprises a carbonate of an alkali or alkaline earth metal.

[0243] In other embodiments, the flame retardant composition comprises cellulose modified with at least one C 10 fatty acid having 6 or more carbon atoms, tall oil fatty acid (TOFA), phosphorylated linseed oil, or phosphorylated downstream corn oil. Preferably, at least one C 10 fatty acid having 6 or more carbon atoms is selected from the group consisting of capric acid, myristic acid, palmitic acid, and combinations thereof.

[0244] As briefly described above, the aerosol generating article of the present invention 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.

[0245] According to the present invention, the downstream section of the aerosol generating article may particularly include a mouthpiece element positioned downstream of the rod of the aerosol generating substrate and longitudinally aligned with the rod of the aerosol generating substrate.

[0246] The mouthpiece element is preferably located at the downstream end or the mouth side end of the aerosol generating article and extends all the way to the mouth side end of the aerosol generating article.

[0247] Preferably, the mouthpiece element comprises a mouthpiece filter segment of at least one fibrous filter material for filtering the aerosol generated from the aerosol generating substrate. Suitable fibrous filter materials will be 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.

[0248] 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 axially aligned in an end-to-end contact relationship with each other.

[0249] In certain embodiments of the present invention, the downstream section may have a mouth-end recess at the downstream end located downstream of the mouthpiece element as described above. The mouth-end recess may be defined by a hollow tubular element provided at the downstream end of the mouthpiece. Alternatively, the mouth-end recess may be defined by an outer wrapper of the mouthpiece element, which extends downstream from the mouthpiece element.

[0250] 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.

[0251] In certain preferred embodiments, the downstream section of the aerosol generating article further comprises a support element located immediately downstream of the rod of the aerosol generating substrate. The mouthpiece element is preferably located downstream of the support element.

[0252] 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.

[0253] The support element may comprise a first hollow tubular segment. In a preferred embodiment, the support element includes a hollow cellulose acetate tube.

[0254] The support elements are 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 of parallel to the longitudinal direction of the rod. In a preferred embodiment, the support elements extend along the longitudinal axis of the rod.

[0255] 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.

[0256] 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.

[0257] The support element may have a length of approximately 5 mm to approximately 15 mm.

[0258] The support element is preferably at least about 6 millimeters in length, and more preferably at least about 7 millimeters in length.

[0259] In a preferred embodiment, the support element has a length of less than about 12 millimeters, more preferably less than about 10 millimeters.

[0260] 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.

[0261] In a preferred embodiment, the support element has a length of about 8 millimeters.

[0262] In some embodiments, the downstream section further comprises an aerosol cooling element located immediately downstream of the support element. The mouthpiece element is preferably located downstream of both the support element and the aerosol cooling element. Particularly preferably, the mouthpiece element is located immediately downstream of the aerosol cooling element. As an example, the mouthpiece element may abut the downstream end of the aerosol cooling element.

[0263] 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.

[0264] 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.

[0265] In some embodiments, the aerosol cooling element is in the shape of a hollow tubular segment defining a cavity that extends throughout from the upstream end to the downstream end of the aerosol cooling element, with a ventilation zone provided along the hollow tubular segment.

[0266] 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, naturally, alternative shapes of tubular elements (e.g., alternative cross-sectional shapes) may be possible.

[0267] 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.

[0268] When used to describe an aerosol cooling element, the term "elongated" means that the aerosol cooling 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.

[0269] The peripheral wall of the aerosol cooling element may have a thickness of less than about 2.5 millimeters, preferably less than about 1.5 millimeters, more preferably less than about 1250 micrometers, and even more preferably less than about 1000 micrometers. In a particularly preferred embodiment, the peripheral wall of the aerosol cooling element has a thickness of less than about 900 micrometers, preferably less than about 800 micrometers.

[0270] The aerosol cooling element may have a length of 5 mm to 15 mm.

[0271] The aerosol cooling element is preferably at least about 6 millimeters in length, and more preferably at least about 7 millimeters in length.

[0272] In a preferred embodiment, the aerosol cooling element has a length of less than about 12 millimeters, more preferably less than about 10 millimeters.

[0273] In some embodiments, the aerosol cooling 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 aerosol cooling 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 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.

[0274] In a particularly preferred embodiment of the present invention, the aerosol cooling element has a length of less than 10 millimeters. For example, in one particularly preferred embodiment, the aerosol cooling element has a length of 8 millimeters. In such embodiments, the aerosol cooling element is therefore relatively shorter in length compared to the aerosol cooling elements of prior art aerosol generating articles. The reduction in the length of the aerosol cooling element is made possible by optimizing the effect of the hollow tubular segments 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 cost advantages to manufacturers, as the cost of hollow tubular segments is typically higher per unit length than the cost of other elements such as mouthpiece elements.

[0275] 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.

[0276] 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.

[0277] In a preferred embodiment, the aerosol cooling element is formed from cellulose acetate.

[0278] The ventilation zone comprises multiple perforations passing 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 peripheral row of perforations preferably contains 8 to 30 perforations.

[0279] The aerosol-generating article according to the present invention may have a ventilation level of at least about 5 percent.

[0280] 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.

[0281] The aerosol generating article according to the present invention preferably has a permeability level of at least about 10 percent, more preferably at least about 15 percent, and even more preferably at least about 20 percent. In a particularly preferred embodiment, the aerosol generating article according to the present invention has a permeability level of at least about 25 percent. While not wishing to be bound by theory, the inventors have found that the temperature reduction caused by introducing colder outside air into the hollow tubular segment through the permeability zone may have a favorable effect on the nucleation and growth of aerosol particles. The rapid cooling induced by introducing outside air into the hollow tubular segment through the permeability zone can be used to favorably promote the favorable nucleation and growth of aerosol droplets. However, at the same time, introducing outside air into the hollow tubular segment has the direct drawback of diluting the aerosol flow delivered to the consumer. Surprisingly, the inventors have found that the dilution effect on the aerosol (which can be evaluated in particular by measuring its effect on the delivery of aerosol-forming agents (such as glycerol) contained in the aerosol generating substrate) is favorably minimized at permeability levels within the ranges described above.

[0282] In some embodiments, the aerosol-generating article may further comprise additional cooling elements that define multiple longitudinally extending channels, for example, to make a large 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.

[0283] In other embodiments, the aerosol cooling element may be provided in the form of a single such cooling element comprising a plurality of longitudinally extending channels.

[0284] One such additional cooling element may define and have a total surface area of ​​approximately 300 square millimeters per millimeter of length to approximately 1,000 square millimeters per millimeter of length.

[0285] 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.

[0286] The aerosol generating article further comprises an upstream section located upstream of the rod of the aerosol generating substrate. The upstream section may comprise one or more upstream elements. In some embodiments, the upstream section may comprise an upstream element located immediately upstream of the rod of the aerosol generating substrate.

[0287] The aerosol-generating article of the present invention preferably includes an upstream element located upstream of and adjacent to the aerosol-generating substrate, wherein the upstream section includes 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 includes 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 helps to prevent any loss of the substrate.

[0288] 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.

[0289] 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.

[0290] 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.

[0291] The porosity or permeability of the upstream element can be advantageously varied to provide the desired overall draw resistance of the aerosol-generating article.

[0292] 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.

[0293] The RTD of the upstream element is preferably 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.

[0294] 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.

[0295] 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 as that used for one of the other components of the aerosol-generating article, such as, for example, a mouthpiece, a cooling element, or a support element. Suitable materials for the upstream element include filter materials, ceramics, polymer materials, cellulose acetate, cardboard, zeolite, or an aerosol-generating substrate. The upstream element is preferably formed from a plug of cellulose acetate.

[0296] The upstream element is preferably formed from a heat-resistant material. For example, the upstream element is preferably formed from a material that can withstand a temperature of up to 350 degrees Celsius. This ensures that the upstream element is not adversely affected by the heating means for heating the aerosol-generating substrate.

[0297] The upstream element preferably has a diameter that is approximately equal to the diameter of the aerosol-generating article.

[0298] The upstream element preferably has a length of from about 1 millimeter to about 10 millimeters, more preferably from about 3 millimeters to about 8 millimeters, and even more preferably from about 4 millimeters to about 6 millimeters. In a particularly preferred embodiment, the upstream element has a length of about 5 millimeters. The length of the upstream element can advantageously vary 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.

[0299] The upstream element is preferably surrounded by a wrapper. The wrapper surrounding the upstream element is preferably a stiff plug wrap, such as, for example, a plug wrap having a basis weight of at least about 80 grams per square meter (gsm), or at least about 100 gsm, or at least about 110 gsm. This provides structural rigidity to the upstream element.

[0300] Preferably, in the aerosol-generating article according to the present invention, the wrapper does not contain metal. As used herein, with reference to the present invention, the term “metal” refers to the content of metal in an oxidized state, i.e., the content of metal in the wrapper as an element in a free form. Therefore, the content of metals such as alkali metals or alkaline earth metals, which may exist in ionic form or be bonded to other elements in one or more flame-retardant compounds in the flame-retardant composition, is not included by the term “metal” as used herein.

[0301] In other words, the wrapper for the aerosol-generating article according to the present invention preferably does not contain metal in an oxidized state of 0.

[0302] Therefore, the aerosol generating article according to the present invention advantageously does not include a metal foil acting as a thermal shielding element. In particular, the aerosol generating substrate is not surrounded by a single such metal foil thermal shielding element.

[0303] The aerosol-generating article according to the present invention described above may be manufactured by a method comprising a first step of providing a continuous rod of aerosol-generating substrate, wherein the density of the aerosol-generating substrate is greater than about 300 milligrams per cubic centimeter. One such method comprises a second step of surrounding the continuous rod of aerosol-generating substrate with a wrapper comprising a flame-retardant composition comprising one or more flame-retardant compounds. The method comprises a third step of cutting the surrounded continuous rod into separate rods, each separate rod being surrounded by a portion of the wrapper comprising the flame-retardant composition.

[0304] The flame-retardant composition may be applied to at least one side of the wrapping substrate of the wrapper by an application process based on size pressing, spraying, printing, or coating.

[0305] The aerosol generating article according to the present invention has been found to be particularly useful in an aerosol generating system that includes an aerosol generating article and an electrically operated aerosol generating device, the aerosol generating device comprising a heater and an elongated heating chamber configured to receive the aerosol generating article such that the aerosol generating substrate of the article is heated in the heating chamber.

[0306] In some embodiments, the heater may be adapted to be inserted into the aerosol generating substrate of the article when the article is placed in the heating chamber. For example, the heater may be in the form of a heating rod or pin.

[0307] In other embodiments, the heater may comprise a substantially cylindrical elongated heating element, and the heating chamber is arranged around the circumferential longitudinal surface of the heater. As a result, during use, the thermal energy supplied by the heater moves radially outward from the surface of the heater to the heating chamber and the aerosol generating article. However, other shapes and configurations of the heater and heating chamber can be used in alternative ways. The heater may comprise a plurality of individual heating elements, which are able to operate independently of each other so that different elements can be activated at different times to heat the aerosol generating article. As an example, the heater may comprise a plurality of axially aligned heating elements that provide a plurality of independent heating zones along the length of the heater. Each heating element may have a length significantly shorter than the total length of the heater. Therefore, when one individual heating element is activated, this heating element supplies thermal energy to a portion of the aerosol generating substrate located radially near the heating element, and does not substantially heat the rest of the aerosol generating substrate. Thus, different sections of the aerosol generating substrate can be heated independently and at different times.

[0308] Alternatively, or additionally, the heater may comprise multiple elongated, longitudinally extending heating elements at different positions around the heater's longitudinal axis. Thus, when one individual heating element is activated, it supplies thermal energy to a longitudinal portion of the aerosol generating substrate positioned substantially parallel and adjacent to the heating element. This arrangement also allows for independent heating of separate portions of the aerosol generating substrate.

[0309] In some of these embodiments, which include heater elements positioned periphery to the heating chamber, the aerosol generating system may further include insulating means positioned between the heating chamber and the outside of the device to reduce heat loss from the heated aerosol generating substrate.

[0310] In a further embodiment, the aerosol generating article includes a susceptor disposed within an aerosol generating substrate, the susceptor being in thermal contact with the aerosol generating substrate, and the heater is in the form of an induction heating device including one or more induction coils. The electromagnetic energy emitted by the induction coils is absorbed by the susceptor, converted into heat, and then transferred to the aerosol generating substrate mainly by conduction.

[0311] The present invention will be further described below with reference to the attached drawings. [Brief explanation of the drawing]

[0312] [Figure 1] Figure 1 shows a schematic side cross-sectional view of an aerosol generating article according to an embodiment of the present invention. [Figure 2] Figure 2 shows a schematic side cross-sectional view of another aerosol generating article according to another embodiment of the present invention. [Modes for carrying out the invention]

[0313] The aerosol generating article 10 shown in FIG. 1 includes a rod 12 of the aerosol generating substrate 12 and a downstream section 14 located downstream of the rod 12 of the aerosol generating substrate. Further, 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 can extend from an upstream or distal end 18 to a downstream or mouth-side end 20.

[0314] The aerosol generating article has an overall length of about 45 millimeters.

[0315] 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 FIG. 1, the upstream end of the support element 18 abuts the downstream end of the rod 12 of the aerosol generating substrate. Further, 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's 22. In the embodiment of FIG. 1, the upstream end of the aerosol cooling element 24 abuts the downstream end of the support element 22. In the embodiment of FIG. 1, the support element 22 and the aerosol cooling element 24 together define an intermediate hollow section 50 of the aerosol generating article 10.

[0316] The support element 22 includes a first hollow tubular segment 26. The first hollow tubular segment 26 is provided in the form of a hollow cylindrical tube made of cellulose acetate. The first hollow tubular segment 26 defines an internal cavity 28 that extends entirely from an upstream end 30 of the first hollow tubular segment to a downstream end 32 of the first hollow tubular segment 20. The internal cavity 28 is substantially empty, and thus substantially unrestricted air flow is possible along the internal cavity 28.​​​​​

[0318] 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.

[0319] The second hollow tubular segment 34 has a length of approximately 8 millimeters, an outer diameter of approximately 7.25 millimeters, and an inner diameter of approximately 3.25 millimeters. Therefore, the thickness of the peripheral wall of the second hollow tubular segment 34 is approximately 2 millimeters. Thus, the ratio between the inner diameter of the first hollow tubular segment 26 and the inner diameter of the second hollow tubular segment 34 is approximately 0.75.

[0320] 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.

[0321] 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.

[0322] The mouthpiece element 42 is provided in the form of a cylindrical plug made of low-density cellulose acetate. The mouthpiece element 42 has a length of approximately 12 mm and an outer diameter of approximately 7.25 mm.

[0323] Rod 12 contains one of the aerosol-generating substrates described above. The density of the aerosol-generating substrate is approximately 600 milligrams per cubic centimeter.

[0324] The rod 12 of the aerosol generating substrate has an outer diameter of approximately 7.25 millimeters and a length of approximately 12 millimeters.

[0325] The aerosol generating article 10 further comprises an elongated susceptor 44 within the rod 12 of the aerosol generating substrate. More specifically, the susceptor 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 44 is positioned radially centrally within the rod and extends effectively along the longitudinal axis of the rod 12. More specifically, the susceptor 44 is in thermal contact with the aerosol generating substrate. The susceptor 44 extends along the entire length of the rod 12, from the upstream end to the downstream end. Substantially, the susceptor 44 has substantially the same length as the rod 12 of the aerosol generating substrate.

[0326] In the embodiment shown in Figure 1, the susceptor 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.

[0327] The upstream section 16 comprises an upstream element 46 located immediately upstream of the rod 12 of the aerosol generating substrate, and the upstream element 46 is 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 44 from detaching. Furthermore, this prevents consumers from accidentally coming into contact with the heating susceptor 44 after use.

[0328] The upstream element 46 is supplied in the form of a cylindrical plug of cellulose acetate surrounded by a rigid wrapper. The upstream cavity element 46 has a length of approximately 5 millimeters. The RTD of the upstream element 46 is approximately 30 millimeters of H2O.

[0329] As shown in Figure 1, the aerosol generating article 10 further comprises a wrapper 70 surrounding the rod 12 of the aerosol generating substrate. The wrapper 70 includes a wrapping substrate having a basis weight of approximately 90 grams per square meter. Furthermore, the wrapper 70 includes a flame-retardant composition comprising one or more flame-retardant compounds.

[0330] More specifically, the flame retardant composition is provided to at least a treated portion 72 of the wrapper that extends between the proximal and distal ends of the rod 12 of the aerosol generating substrate. The treated portion 72 contains one or more flame retardant compounds at a rate of about 3.5 grams per square meter of the surface area of ​​the treated portion 72. Thus, the treated portion 72 of the wrapper 70 has a total basis weight greater than the basis weight of the wrapping substrate. In the embodiment of Figure 1, the treated portion 72 has a length substantially matching the length of the rod 12 of the aerosol generating substrate and extends substantially over the entire outer surface area of ​​the rod 12 of the aerosol generating substrate.

[0331] The aerosol-generating article 110 shown in Figure 2 has many features in common with the aerosol-generating article 10 in Figure 1, and will be described below insofar as it differs from the aerosol-generating article 10.

[0332] As shown in Figure 2, the aerosol generating article 110 comprises a rod 12 of the aerosol generating substrate 12 and a modified downstream section 114 located downstream of the rod 12 of the aerosol generating substrate. Furthermore, the aerosol generating article 110 does not include an upstream section.

[0333] Similar to the downstream section 14 of the aerosol generating article 10, the modified downstream section 114 of the aerosol generating article 110 includes a support element 22 located immediately downstream of the rod 12 of the aerosol generating substrate, the support element 22 being longitudinally aligned with the rod 12, and the upstream end of the support element 22 abutting against the downstream end of the rod 12 of the aerosol generating substrate.

[0334] Furthermore, the modified downstream section 114 includes an aerosol cooling element 124 located immediately downstream of the support element 22, the aerosol cooling element 124 being longitudinally aligned with the rod 12 and the support element 22. More specifically, the upstream end of the aerosol cooling element 124 abuts against the downstream end of the support element 22.

[0335] In contrast to the downstream section 14 of the aerosol generating article 10, the aerosol cooling element 124 of the modified downstream section 114 comprises a plurality of longitudinally extending channels that provide low or substantially null resistance to the passage of air through the rod. More specifically, the aerosol cooling element 124 is preferably formed from a non-porous sheet material selected from the group including metal foil, polymer sheets, and substantially non-porous paper or cardboard. In particular, in the embodiment illustrated in Figure 2, the aerosol cooling element 124 is provided in the form of crimped sheets and sheet aggregates of polylactic acid (PLA). The aerosol cooling element 124 has a length of about 8 millimeters and an outer diameter of about 7.25 millimeters.

[0336] Similar to the embodiment in Figure 1, the aerosol generating article 110 in Figure 2 further comprises a wrapper 70 surrounding the rod 12 of the aerosol generating substrate. The wrapper 70 includes a wrapping substrate having a basis weight of about 90 grams per square meter. Furthermore, the wrapper 70 includes a flame-retardant composition comprising one or more flame-retardant compounds.

[0337] More specifically, the flame retardant composition is provided to at least a treated portion 72 of the wrapper that extends between the proximal and distal ends of the rod 12 of the aerosol generating substrate. The treated portion 72 contains one or more flame retardant compounds at a rate of about 3.5 grams per square meter of the surface area of ​​the treated portion 72. Thus, the treated portion 72 of the wrapper 70 has a total basis weight greater than the basis weight of the wrapping substrate. In the embodiment of Figure 1, the treated portion 72 has a length substantially matching the length of the rod 12 of the aerosol generating substrate and extends substantially over the entire outer surface area of ​​the rod 12 of the aerosol generating substrate.

Claims

1. An aerosol generating article for generating an inhalable aerosol upon heating, wherein the aerosol generating article is A rod of an aerosol generating substrate, wherein the aerosol generating substrate comprises at least an aerosol forming body, and the aerosol generating substrate has an aerosol forming body content of at least about 10 percent by dry weight, The downstream section located downstream of the rod of the aerosol generating substrate, The upstream section located upstream of the rod of the aerosol generating substrate, the upstream section being formed of a filter material, and The aerosol generating substrate comprises a rod and a wrapper that surrounds at least a portion of the upstream section, The density of the aerosol generating substrate is more than approximately 300 milligrams per cubic centimeter. An aerosol-generating article wherein the wrapper comprises a flame-retardant composition containing one or more flame-retardant compounds.

2. The aerosol generating article according to claim 1, wherein the density of the aerosol generating substrate is more than approximately 350 milligrams per cubic centimeter.

3. The aerosol generating article according to claim 1, wherein the density of the aerosol generating substrate is more than approximately 400 milligrams per cubic centimeter.

4. The aerosol generating article according to any one of claims 1 to 3, wherein the rod of the aerosol generating substrate includes an aggregate of sheets of homogenized tobacco material.

5. The aerosol generating article according to any one of claims 1 to 3, wherein the rod of the aerosol generating substrate comprises a gel composition, and the gel composition comprises at least one gelling agent, at least one of an alkaloid compound and a cannabinoid compound, and an aerosol forming body.

6. The aerosol generating article according to any one of claims 1 to 5, wherein the rod of the aerosol generating substrate further comprises a susceptor element disposed within the aerosol generating substrate.

7. The aerosol generating article according to any one of claims 1 to 6, wherein the wrapper comprises a wrapping substrate and a layer comprising a flame retardant composition provided on the surface of the wrapping substrate facing the aerosol generating substrate, the surface of the wrapping substrate facing away from the aerosol generating substrate, or both.

8. The aerosol generating article according to any one of claims 1 to 7, wherein the flame retardant composition comprises a polymer and a mixed salt based on at least one mono, di, and / or tricarboxylic acid, at least one polyphosphate, pyrophosphate, and / or phosphoric acid, and a hydroxide or alkaline earth metal salt, wherein at least one mono, di, and / or tricarboxylic acid and a hydroxide or salt form a carboxylate, and at least one polyphosphate, pyrophosphate, and / or phosphoric acid and a hydroxide or salt form a phosphate.

9. The aerosol generating article according to claim 8, wherein the flame retardant composition further comprises an alkali or alkaline earth metal carbonate.

10. The flame retardant composition contains at least one C 10 An aerosol generating article according to any one of claims 1 to 7, comprising the above fatty acids, tall oil fatty acids (TOFA), phosphorylated linseed oil, and cellulose modified with phosphorylated downstream corn oil.

11. The aerosol generating article according to any one of claims 1 to 10, wherein the rod of the aerosol generating substrate has a length of less than about 40 millimeters.

12. The aerosol generating article according to any one of claims 1 to 11, wherein the rod of the aerosol generating substrate has a length of at least about 10 millimeters.

13. The aerosol generating article according to any one of claims 1 to 12, wherein the total length of the aerosol generating article is less than approximately 70 millimeters.

14. The aerosol generating article according to any one of claims 1 to 13, wherein the wrapper does not contain metal.

15. A method for manufacturing an aerosol generating article for generating an inhalable aerosol upon heating, To provide a continuous rod of aerosol generating substrate, wherein the density of the aerosol generating substrate is greater than approximately 300 milligrams per cubic centimeter, the aerosol generating substrate contains at least an aerosol forming body, and the aerosol generating substrate has an aerosol forming body content of at least approximately 10 percent on a dry weight basis. A wrapper comprising a flame-retardant composition containing one or more flame-retardant compounds surrounds the continuous rod of the aerosol-generating substrate, The process of cutting the enclosed continuous rod into separate rods, each separate rod being enclosed by a portion of the wrapper containing the flame-retardant composition, To provide the downstream section at a position downstream of the rod of each separate aerosol generating substrate, To provide an upstream section at an upstream position of each separate aerosol generating substrate rod, wherein each upstream section is formed of a filter material and the wrapper surrounds at least a portion of the upstream section, Methods that include...

16. The method according to claim 15, wherein the layer of the flame retardant composition is applied to at least one side of the wrapping substrate of the wrapper by an application process based on size pressing, spraying, printing, or coating.

17. An aerosol generating system comprising an electrically operated aerosol generating device and an aerosol generating article according to any one of claims 1 to 14, wherein the aerosol generating device includes means for heating the rods of the aerosol generating substrate to a temperature sufficient to generate an aerosol from the aerosol generating substrate.

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