Aerosol-generating items

Abstract

The present invention provides an aerosol-forming substrate equipped with an elongated susceptor. [Solution] The aerosol generating article (10) comprises a plurality of elements assembled in the form of a rod having a mouth end (70) and a distal end (80) located upstream from the mouth end. The plurality of elements comprises an aerosol forming substrate (20) having an elongated susceptor (25) positioned along its longitudinal axis within the aerosol forming substrate. A plug element (90) is located upstream of and adjacent to the aerosol forming substrate within the rod. The plug element (90) thereby prevents direct physical contact with the distal end of the elongated susceptor (25) positioned along its longitudinal axis within the aerosol forming substrate (20).

Description

Technical Field

[0001] The present invention relates to an aerosol generating article comprising an aerosol forming substrate and an elongate susceptor disposed within the aerosol forming substrate. In particular, the present invention relates to an inductively heatable aerosol generating article.

Background Art

[0002] Inductively heatable aerosol generating articles comprising an aerosol forming substrate and an elongate susceptor disposed within the aerosol forming substrate are well known from the prior art. For example, International Patent Publication WO 2015 / 176898 discloses an aerosol generating article having an elongate susceptor disposed within an aerosol forming substrate plug. The aerosol generating article comprises a plurality of elements in the form of rods and is adapted to be used in an electrically operated aerosol generating device comprising an inductor for generating heat within the elongate susceptor. The position of the elongate susceptor may depend on the method of manufacturing the aerosol forming substrate comprising the susceptor. However, the elongate susceptor typically extends at least to the distal end of the aerosol forming substrate plug. This exposed position of at least the end of the susceptor can change the position of the susceptor during handling or transport of the article, which can change the consistency of the article.

[0003] Therefore, it would be desirable to have an aerosol generating article comprising an aerosol forming substrate and an elongate susceptor disposed within the aerosol forming substrate that improves the consistency of the article.

Summary of the Invention

[0004] The present invention provides an aerosol generating article comprising a plurality of elements assembled in the form of a rod having a mouth end and a distal end located upstream from the mouth end. The plurality of elements comprises an aerosol forming substrate having an elongated susceptor positioned along its longitudinal axis within the aerosol forming substrate. A plug element is located upstream of and adjacent to the aerosol forming substrate within the rod. The plug element prevents direct physical contact with the distal end of the elongated susceptor positioned along its longitudinal axis within the aerosol forming substrate.

[0005] The plug element prevents direct contact with the distal end of the susceptor, thus preventing displacement or deformation of the susceptor during handling or transport of the article. Susceptors, which are typically metal components and relatively heavy, tend to detach from the aerosol-forming substrate during transport of the article. Therefore, the plug element also prevents the susceptor from falling off the aerosol-generating article if it detaches, for example, during transport of the article. Further advantages of the plug element protecting the distal end of the aerosol-forming substrate may relate to aesthetic or branding reasons. The plug element can be used to cover the distal end of an article, which can improve its appearance. It can also provide information on the article, for example, brand, contents, flavor, or electronically operated devices used with the article.

[0006] The plug element can fix the shape and position of the susceptor within the aerosol-forming substrate, thereby improving or ensuring consistency from article to article. In addition, the plug element may also improve the aesthetic appearance of the article and may provide a simple way to provide the user with further information about the article.

[0007] As used herein, the terms “upstream” and “downstream” are used to describe the relative position of elements or parts of an aerosol-generating article in relation to the direction in which a user inhales the aerosol-generating article during its use. The aerosol-generating article is in the form of a rod having two ends: a mouth-side end (i.e., the proximal end, through which the aerosol exits the aerosol-generating article and is delivered to the user) and a distal end. During use, the user can inhale through the mouth-side end. The distal end may also be called the upstream end and is located upstream of the mouth-side end.

[0008] The aerosol generating article is preferably a smoking article that generates an aerosol. Furthermore, the aerosol generating article is preferably a smoking article that generates a nicotine-containing aerosol.

[0009] The plug element may be a porous element. A porous plug element is preferable as it does not change the draw resistance of the aerosol-generating article. The plug element is preferably porosity of at least 50 percent in the longitudinal direction of the rod. The plug element is preferably porosity of 50 percent to 90 percent. The porosity of the plug element in the longitudinal direction is defined by the ratio of the cross-sectional area of ​​the material forming the plug element to the internal cross-sectional area of ​​the aerosol-generating article at the location of the plug element. This definition of porosity can also be appropriately applied to any other element of the aerosol-generating article.

[0010] The plug element may be made of a porous material or may have multiple openings. This can be achieved, for example, by laser drilling.

[0011] The permeability of the plug element may allow the user to draw air through the rod via the plug element.

[0012] It is preferable that the multiple openings are uniformly distributed across the entire cross-section of the plug element.

[0013] The size of the multiple openings is preferably such that the distal end of the aerosol-forming substrate is not visible from above.

[0014] The porosity or permeability of the plug element can be varied to control the draw resistance through the aerosol-generating article.

[0015] The draw-out resistance (RTD) of the plug element is often 20 mmWG to 40 mmWG, and preferably 25 mmWG to 35 mmWG (millimeter water level gauge). Preferably, the RTD of the plug element does not exceed 30 mmWG. Preferably, the draw-out resistance (RTD) of the plug element is 1 to 5 mmWG per millimeter of length of the plug element, for example, 2.5 mmWG per millimeter of length of the plug element. The plug element may have the same RTD as an element made of an aerosol-forming substrate equipped with an elongated susceptor.

[0016] Alternatively, the plug element may be airtight and formed of a material that is impermeable to air. In such embodiments, the article may be configured so that air flows through the side walls into the rod through holes defined in, for example, cigarette paper or wrapper material.

[0017] The plug element may be made of any material suitable for use in an aerosol generating article for an induction-heatable aerosol generator. The plug element may be made of the same material used in the article, for example, the same material used in a conventional mouthpiece filter, an aerosol cooling element, or a support element. Exemplary materials include filter materials, ceramics, polymer materials, cellulose acetate, cardboard, non-induction-heatable metals, zeolites, or aerosol-forming substrates.

[0018] The plug element is preferably made of a heat-resistant material. In this specification, a heat-resistant material for the plug element means that the plug element can withstand temperatures up to approximately 350°C. This ensures that the plug element is not affected by a heated susceptor or a heated aerosol-forming substrate.

[0019] It is preferable that the plug element does not change in consistency, geometric shape, or optical properties during the use of the article.

[0020] Preferably, the plug element does not generate any additional substances in addition to the aerosol generated during use of the article.

[0021] The plug element has a diameter approximately equal to the diameter of the aerosol-generating article. Preferably, the plug element has a diameter of 5 to 10 mm. The plug diameter is preferably greater than 5 mm, for example, 6 to 8 mm. The plug element has a length that can be defined as a dimension along the long axis of the aerosol-generating article. The length of the plug element can be 1 to 10 mm, for example, 4 to 8 mm or 5 to 7 mm. The plug element is preferably substantially cylindrical. Preferably, the plug element is less than 8 mm in length. To facilitate the assembly of the aerosol-generating article, the plug element is preferably at least 2 mm long, preferably at least 3 mm, or at least 5 mm long.

[0022] As a general rule, whenever a value is mentioned throughout this specification, it is understood that the value should be explicitly disclosed. However, it is also understood that the value does not have to be strictly specific for technical considerations.

[0023] The plug elements may be separate elements. The aforementioned minimum size of the plug element length facilitates or enables the use of conventional combiners for assembling multiple elements into a rod shape.

[0024] The plug element may have a homogeneous structure. The plug element may have, for example, a homogeneous texture and appearance. The plug element may have, for example, a continuous and regular surface across its entire cross-section, or it may not have, for example, recognizable symmetry. It is preferable that at least the distal end of the plug element has a homogeneous structure. A homogeneous distal end of the plug element is advantageous for the consistency of the plug element across the entire cross-section of the article.

[0025] The plug element may have an inner surface defining a recess, which is preferably located at least at the proximal end of the plug element. The recess is directed toward the aerosol-forming substrate. The recess is positioned within the plug element such that the plug element does not come into contact with the elongated susceptor placed in the aerosol-forming substrate, or only comes into contact in a limited area. The recess may be positioned in the center of the plug element such that the central portion of the proximal end of the plug element does not come into contact with the elongated susceptor. The inner surface of the recess may have, for example, a concave shape, such as a dome shape. The diameter of the recess in the radial direction of the rod is preferably larger than the radial extension of the elongated susceptor.

[0026] Providing recesses within the plug element to prevent physical contact with the susceptor, and generally limiting the contact area between the plug element and the aerosol-forming substrate, can prevent overheating of the plug element (especially those parts of the plug element that come into contact with the susceptor). This reduces the risk of overheating or carbonization of the plug element and expands the range of suitable materials for manufacturing the plug element.

[0027] The aerosol-forming substrate may be a solid aerosol-forming substrate. The aerosol-forming substrate may contain a tobacco-containing material that includes volatile tobacco-flavored compounds released from the substrate upon heating. Alternatively, the aerosol-forming substrate may contain a non-tobacco material. The aerosol-forming substrate may further contain aerosol-forming bodies. Examples of suitable aerosol-forming bodies are glycerin and propylene glycol.

[0028] When the aerosol-forming substrate is a solid aerosol-forming substrate, the solid aerosol-forming substrate may include one or more of tobacco leaves, tobacco leaves, fragments of tobacco stems, reconstituted tobacco, homogenized tobacco, extruded tobacco and expanded tobacco, and may include, for example, one or more of powders, granules, pellets, fragments, spaghetti-like threads, flakes or sheets. The solid aerosol-forming substrate may be in a form not contained in a container, or an appropriate container or cartridge may be provided. For example, the aerosol-forming material of the solid aerosol-forming substrate may be contained within a paper or other wrapper and may have the form of a plug. When in the form of a plug wrapped with the aerosol-forming substrate, the entire plug including any wrapper is considered to be the aerosol-forming substrate.

[0029] Optionally, the solid aerosol-forming substrate may include additional tobacco or non-tobacco volatile flavor compounds released upon heating of the solid aerosol-forming substrate. The solid aerosol-forming substrate may also include, for example, capsules containing additional tobacco or non-tobacco volatile flavor compounds, and such capsules may dissolve during heating of the solid aerosol-forming substrate.

[0030] The aerosol-forming substrate may comprise one or more homogenized tobacco material sheets that are gathered in a rod shape, surrounded by a wrapper, and cut to provide individual plugs of the aerosol-forming substrate. The aerosol-forming substrate preferably includes an assembly of crimped sheets of homogenized tobacco material.

[0031] The aerosol-forming tobacco substrate preferably comprises a tobacco material, a fiber, a binder, and an aerosol former, preferably a crimped tobacco sheet. The tobacco sheet is preferably a cast leaf. The cast leaf is a form of reconstituted tobacco formed from a slurry comprising tobacco particles, fiber particles, an aerosol former, a binder, and, for example, flavor.

[0032] The wrapper can be any non-tobacco material suitable for enclosing the elements of the aerosol-generating article in the form of a rod. The wrapper holds multiple elements within the aerosol-generating article when the article is assembled into a rod.

[0033] The aerosol-forming substrate may be substantially cylindrical in shape. The aerosol-forming substrate may also be substantially elongated. The aerosol-forming substrate may also have a length and a circumference substantially perpendicular to this length.

[0034] Furthermore, the length of the aerosol-forming substrate may be 10 millimeters. Alternatively, the length of the aerosol-forming substrate may be 12 millimeters. Furthermore, the diameter of the aerosol-forming substrate may be between 5 millimeters and 12 millimeters.

[0035] As used herein, the term “susceptor” refers to a material capable of converting electromagnetic energy into heat. When located in a fluctuating electromagnetic field, eddy currents induced within the susceptor cause it to heat up. Because the elongated susceptor is in thermal contact with the aerosol-forming substrate, the aerosol-forming substrate is heated by the susceptor. The susceptor has a length dimension greater than its width dimension or thickness dimension, for example, twice its width dimension or thickness dimension. Thus, the susceptor can be described as an elongated susceptor. The susceptors are arranged substantially along the long axis within the rod. This means that the length dimension of the elongated susceptor is aligned substantially parallel to the long axis of the rod, for example, within ±10 degrees from parallel to the long axis of the rod. In a preferred embodiment, the elongated susceptor may be located radially centrally within the rod and extend along the long axis of the rod.

[0036] The susceptor is preferably in the form of a pin, rod, strip, or blade. The susceptor is preferably 5 to 15 mm in length, for example 6 to 12 mm, or 8 to 10 mm. The susceptor is preferably 1 to 5 mm in width and may have a thickness of 0.01 mm to 2 mm, for example 0.5 mm to 2 mm. In a preferred embodiment, the susceptor may have a thickness of 10 to 500 micrometers, but 10 to 100 micrometers is even more preferred. If the outer shape of the susceptor has a constant cross-section, for example a circular cross-section, it has a preferred width or diameter of 1 to 5 mm. If the susceptor is in the form of a strip or blade, the width of the strip or blade is preferably 2 to 8 mm, more preferably 3 to 5 mm, for example 4 mm, and the thickness is preferably 0.03 to 0.15 mm, more preferably 0.05 to 0.09 mm, for example 0.07 mm, and it is preferable to have a rectangular shape.

[0037] The elongated susceptor is preferably the same length as or shorter than the aerosol-forming substrate.

[0038] The susceptor can be formed from any material that can be inductively heated to a temperature sufficient to generate an aerosol from the aerosol-forming substrate. Preferred susceptors include metals or carbon. Preferred susceptors may include or consist of ferromagnetic materials, such as ferromagnetic alloys, ferrite iron, or ferromagnetic steel or stainless steel. Suitable susceptors may be aluminum or contain aluminum. Preferred susceptors may be formed from 400 series stainless steel, such as grade 410, or grade 420, or grade 430 stainless steel. Different materials disperse different amounts of energy when positioned in an electromagnetic field having similar values ​​of frequency and magnetic field strength. Thus, any of the susceptor parameters, such as material type, length, width, and thickness, can be varied to provide the desired power distribution in a known electromagnetic field.

[0039] A preferred susceptor may be heated to a temperature exceeding 250°C. A suitable susceptor may comprise a non-metallic core on which a metal layer, such as a metal strip formed on the surface of a ceramic core, is arranged. The susceptor may have a protective outer layer enclosing the susceptor, such as a protective ceramic layer or a protective glass layer. The susceptor may also comprise a protective coating formed of glass, ceramic, or an inert metal, formed on the core of the susceptor material.

[0040] The susceptors are arranged in thermal contact with the aerosol-forming substrate. Thus, as the temperature of the susceptors increases, the aerosol-forming substrate is heated, and an aerosol is formed. Preferably, the susceptors are arranged, for example, within the aerosol-forming substrate, in direct physical contact with the aerosol-forming substrate.

[0041] 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 laminated in physical contact with the second susceptor material. The second susceptor material preferably has a Curie temperature lower than 500°C. 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 material such as stainless steel. The second susceptor material is preferably used primarily to indicate when the susceptor has reached a specific temperature (that temperature being the Curie temperature of the second susceptor material). The Curie temperature of the second susceptor material can be used to regulate the temperature of the entire susceptor during operation. Therefore, the Curie temperature of the second susceptor material must be below the ignition point of the aerosol-forming substrate. Suitable materials for the second susceptor may include nickel and certain nickel alloys.

[0042] 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 heating of the aerosol-forming substrate and the temperature control of that heating can be separated. The first susceptor material is preferably a magnetic material having a Curie temperature of over 500°C. 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 can preferably be selected to be lower than 400°C, preferably lower than 380°C, or lower than 360°C. 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. That is, it is preferable that its second Curie temperature is approximately the same as the temperature to which the susceptor should be heated in order to generate aerosols from the aerosol-forming substrate. The second Curie temperature may be, for example, in the range of 200°C to 400°C, or 250°C to 360°C. The second Curie temperature of the second susceptor material may be selected such that, when heated by a susceptor having a temperature equal to that second Curie temperature, the overall average temperature of the aerosol-forming substrate does not exceed 240°C.

[0043] The aerosol-generating article may be substantially cylindrical in shape. The aerosol-generating article may also be substantially elongated. The aerosol-generating article may also have a length and circumference substantially perpendicular to its length.

[0044] The total length of the aerosol generating article can be 30 mm to 100 mm. In a preferred embodiment, the total length of the aerosol generating article is 40 mm to 55 mm, for example, 47 mm to 53 mm.

[0045] The outer diameter of the aerosol-generating article can be 5 mm to 12 mm, for example, 6 mm to 8 mm. In one preferred embodiment, the aerosol-generating article has an outer diameter of 7.2 mm ± 10 percent.

[0046] The aerosol generating article may include a mouthpiece element. The mouthpiece element may be located at the oral end or the downstream end of the aerosol generating article.

[0047] The mouthpiece element may comprise at least one filter segment. The filter segment may be a cellulose acetate filter plug made of cellulose acetate tow. The filter segment may have low or very low particle filtration efficiency. The filter segment may be spaced along its longitudinal axis from the aerosol-forming substrate. In one embodiment, the filter segment is 7 millimeters long, but may have a length of 5 to 14 millimeters.

[0048] The mouthpiece element is the final downstream component of the aerosol-generating article. The user contacts the mouthpiece element to allow the aerosol generated by the aerosol-generating article to pass through the mouthpiece element and be delivered to the user. Thus, the mouthpiece element is positioned downstream of the aerosol-forming substrate.

[0049] The mouthpiece element preferably has an outer diameter approximately equal to the outer diameter of the aerosol generating article. The mouthpiece element may have an outer diameter of 5 mm to 10 mm, for example, 6 mm to 8 mm. In a preferred embodiment, the mouthpiece element has an outer diameter of 7.2 mm ± 10 percent. The mouthpiece element may have a length of 5 mm to 25 mm, and preferably 10 mm to 17 mm. In a preferred embodiment, the mouthpiece element has a length of 12 mm to 14 mm. In a preferred embodiment, the mouthpiece element has a length of 7 mm.

[0050] The aerosol-generating article may be located immediately downstream of the aerosol-forming substrate and may also be equipped with a support element that can be located adjacent to the aerosol-forming substrate.

[0051] 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.

[0052] The support element may include a hollow tubular element. In a preferred embodiment, the support element comprises a hollow cellulose acetate tube.

[0053] The support element preferably has an outer diameter that is approximately equal to the outer diameter of the aerosol-generating article.

[0054] The support element may have an outer diameter of 5 mm to 12 mm, for example, 5 mm to 10 mm or 6 mm to 8 mm. In a preferred embodiment, the support element has an outer diameter of 7.2 mm ± 10 percent. The support element may have a length of 5 mm to 15 mm. In a preferred embodiment, the support element has a length of 8 mm.

[0055] The aerosol generating article may be equipped with an aerosol cooling element. The aerosol cooling element may be located downstream of the aerosol forming substrate; for example, the aerosol cooling element may be located immediately downstream of a support element and adjacent to the support element.

[0056] The aerosol cooling element may be located between the support element and a mouthpiece element located at the furthest downstream end of the aerosol generating article.

[0057] As used herein, the term “aerosol cooling element” is used to describe an element having a large surface area and low draw resistance. During use, aerosols formed by volatile compounds released from an aerosol-forming substrate are drawn through the aerosol cooling element before being carried to the mouth end of the aerosol-generating article. In contrast to filters with high draw resistance (e.g., filters formed from bundles of fibers), aerosol cooling elements have low draw resistance. Chambers and recesses within the aerosol-generating article, such as expansion chambers and support elements, are also not considered aerosol cooling elements.

[0058] The aerosol cooling element preferably has a porosity in the longitudinal direction of more than 50 percent. The airflow path passing through the aerosol cooling element is preferably relatively unrestricted. The aerosol cooling element may be an assembly of sheets or an assembly of crimped sheets. 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, or any combination thereof.

[0059] In a preferred embodiment, the aerosol cooling element comprises an assembly of biodegradable material sheets. For example, an assembly of non-porous paper sheets, or an assembly of biodegradable polymer materials such as polylactic acid or grades of Mater-Bi® (a commercially available family of starch-based copolyesters).

[0060] The aerosol cooling element preferably comprises an aggregate of PLA sheets, and more preferably an aggregate of crimped PLA sheets. The aerosol cooling element may be formed from sheets having a thickness of 10 micrometers to 250 micrometers (e.g., 50 micrometers). The aerosol cooling element may be formed from an aggregate of sheets having a width of 150 millimeters to 250 millimeters. The aerosol cooling element may have a specific surface area of ​​300 square millimeters to 1000 square millimeters per millimeter of length and 10 square millimeters to 100 square millimeters per mg of weight. In some embodiments, the aerosol cooling element may be formed from an aggregate of material sheets having a specific surface area of ​​about 35 square millimeters per mg of weight. The aerosol cooling element may have an outer diameter of 5 millimeters to 10 millimeters, for example, 7 millimeters.

[0061] In some preferred embodiments, the length of the aerosol cooling element is 10 to 15 millimeters. Preferably, the length of the aerosol cooling element is 10 to 14 millimeters, for example, 13 millimeters.

[0062] In an alternative embodiment, the length of the aerosol cooling element is 15 to 25 millimeters. Preferably, the length of the aerosol cooling element is 16 to 20 millimeters, for example, 18 millimeters.

[0063] As an aerosol passes through an aerosol cooling element, its temperature decreases due to the transfer of thermal energy to the element. Furthermore, water droplets liquefied from the aerosol may adsorb onto the material of the aerosol cooling element. Depending on the type of material forming the aerosol cooling element, the water content of the aerosol can be reduced by 0 to 90 percent. For example, when the aerosol cooling element contains polylactic acid, the water content is not reduced significantly. For instance, when starch-based materials (e.g., Mater-Bi) are used to form the aerosol cooling element, the water reduction can be approximately 40 percent. Therefore, the water content within the aerosol can be determined by the choice of material forming the aerosol cooling element.

[0064] For example, aerosols formed by heating tobacco-derived aerosol-forming substrates typically contain phenolic compounds. Aerosol cooling elements can reduce phenol and cresol levels by 90 to 95 percent.

[0065] Generally available electronic heating devices are designed to use aerosol-generating articles of predetermined dimensions, particularly of a predetermined standard length. For an aerosol-generating article to be usable with these standard heating devices, its overall length should be standard. Typically, such a standard length is 45 millimeters. Furthermore, it is preferable that the dimensions and arrangement of the aerosol-forming substrate, which is contained within the aerosol-generating article and heated by the heating device's heating element, remain unchanged.

[0066] Therefore, when a plug element is added to an aerosol generator, the length of the article increases by the length of the plug element. Consequently, the length of the plug element should not exceed 8 mm so as not to excessively extend the overall length of the aerosol generating article. An aerosol generating article with a standard length of 45 mm is preferably an article with a length of 47 mm to 53 mm when a plug element is provided.

[0067] However, the length of the article may be kept constant by compensating for the added length of the plug element through shortening another element or segment of the article (preferably the aerosol cooling element). However, it is preferable that the properties of the article are not altered by doing so.

[0068] Multiple experiments have shown that, in aerosol generating articles of standard length, desired aerosol cooling or reduction of phenolic compounds can be achieved even with aerosol cooling elements shorter than the standard 18 mm aerosol cooling element. In particular, shorter aerosol cooling elements made of polylactic acid have been found to exhibit comparable cooling or different smoke chemical properties.

[0069] Therefore, the additional length of the plug element is compensated for by shortening the aerosol cooling element. Shortening of the aerosol cooling element, or further shortening of the aerosol cooling element, can also be achieved by providing a hollow tube.

[0070] Some materials used in aerosol generating articles are also more cost-intensive than others. For example, the materials used for aerosol cooling elements, particularly crimped polylactic acid sheets, are expensive. Thus, in aerosol generating articles, the length of the aerosol cooling element may be reduced compared to such elements in standard aerosol generating articles for electronic devices. Typically, the standard length of an aerosol cooling element is 18 millimeters. To maintain the overall length of the aerosol generating article at a predetermined length (e.g., 45 millimeters), the length of the mouthpiece element may be extended to compensate for the shorter length of the aerosol cooling element.

[0071] Surprisingly, it was found that the aerosol cooling element could be shortened to some extent without adversely affecting the chemical properties of the smoke. It was also found that, surprisingly, this could be done without altering the movement of smoke components through the mouthpiece, provided that the length difference was compensated for within the mouthpiece. In particular, when a hollow tube was used to compensate for the overall length, no change in smoke components due to the mouthpiece was detected. It has been found that shortening the aerosol cooling element by just a few millimeters leads to significant cost savings. The extension of the mouthpiece is preferably realized by providing a hollow tube. Hollow tubes (e.g., cardboard tubes) can be manufactured at very low cost, and as a result, cost savings can be achieved by partially "replacing" the aerosol cooling element in the tobacco portion of the aerosol generating article with a hollow tube in the mouthpiece portion of the aerosol generating article.

[0072] Therefore, the mouthpiece element may have a hollow tube.

[0073] If a hollow tube is present, it is preferable to position it at the downstream end of the mouthpiece element, and consequently at the downstream end of the aerosol generating article. This imparts the effect of a recessed filter to the aerosol generating article. In this way, when using the electronic smoking system, the user can be provided with a tactile sensation equivalent to that obtained when smoking a conventional cigarette, provided by a recessed filter.

[0074] The hollow tube of the mouthpiece element may be made of cardboard. The hollow tube may also be made of a different material (e.g., paper or thin plastic sheet material). Preferably, the hollow tube has stability that allows for handling of the aerosol-generating article.

[0075] The length of the hollow tube may be 3 to 8 millimeters. A length of 5 millimeters is preferable.

[0076] The length of the hollow tubes mentioned above, particularly the length of the cardboard tubes, has been shown to enable good manufacturing of the tubes and good handling of the tubes during assembly of the mouthpiece elements and aerosol generating articles.

[0077] The wall thickness of the hollow tube is preferably 100 to 300 micrometers, for example, 200 micrometers. When inserting an aerosol-generating article into an electronic heating device, consumers typically hold the aerosol-generating article at its proximal end or push it at its proximal end. Since the hollow tube is preferably the most proximal segment of the aerosol-generating article, the aerosol-generating article is typically pushed by the hollow tube. The aforementioned wall thickness has been found to satisfy the stability requirements for the hollow tube, particularly the cardboard tube, when the aerosol-generating article is inserted into the electronic heating device.

[0078] The aerosol generating article according to the present invention preferably comprises a plug element, an aerosol forming substrate including a susceptor, a support element, an aerosol cooling element, and a mouthpiece element. The mouthpiece element comprises at least one filter element and optionally includes a hollow tube. In such an aerosol generating article, the support element is located downstream of the aerosol forming substrate, and the aerosol cooling element is located downstream of the support element.

[0079] In the aerosol generating article according to the present invention, comprising a mouthpiece element having a filter segment and a hollow tube, the hollow tube is preferably positioned at the distal end of the rod. The length of the mouthpiece element may be extended, particularly by adding or extending the hollow tube, to compensate for the shortened length of the aerosol cooling element, so that the overall length of the aerosol generating article is maintained at a predetermined overall length. The overall length of the article is preferably 45 millimeters, and the length of the aerosol cooling element of the tobacco element is preferably up to 15 millimeters. The length of the mouthpiece element, preferably the length of the hollow tube, is adapted according to the length of the aerosol cooling element so that the overall length of the aerosol generating article is maintained at a predetermined overall length.

[0080] The possibility of having a shortened aerosol cooling element, the provision of an additional hollow tube within the mouthpiece element to compensate for such a shortened aerosol cooling element, its advantages and specific features are described in detail in European Patent Application No. 15173224.5. That application and its contents regarding the aforementioned length compensation are incorporated herein by reference.

[0081] The aerosol generating article preferably comprises five to six elements or segments.

[0082] Elements of the aerosol-forming article, such as the aerosol-forming substrate, plug elements, and any other optional elements of the aerosol-generating article (such as support elements, aerosol cooling elements, and mouthpiece elements), are surrounded by an outer wrapper. The outer wrapper may be formed from any suitable material or combination of materials. The outer wrapper is preferably cigarette paper.

[0083] The present invention will be further described in relation to embodiments, which are illustrated by the following drawings. [Brief explanation of the drawing]

[0084] [Figure 1] Figure 1 is a schematic cross-sectional view of an embodiment of an aerosol generating article equipped with a plug element. [Figure 2] Figure 2 is a schematic cross-sectional view of another embodiment of an aerosol generating article equipped with a recessed filter. [Figure 3] Figure 3 shows a magnified view of the recessed plug element. [Figure 4] Figure 4 shows another embodiment of the plug element. [Modes for carrying out the invention]

[0085] Figure 1 illustrates an aerosol generating article 10. The aerosol generating article 10 includes five elements arranged coaxially: a plug element 90, an aerosol forming substrate 20, a support element 30, an aerosol cooling element 40, and a mouthpiece 50. Each of these five elements is substantially cylindrical and has substantially the same diameter. These five elements are arranged in a continuous line and surrounded by an outer wrapper 60 to form a cylindrical rod. A blade-shaped susceptor 25 is located within the aerosol forming substrate and is in contact with it. The susceptor 25 has approximately the same length as the aerosol forming substrate and is located along the radial central axis of the aerosol forming substrate.

[0086] The susceptor 25 is made of ferrite iron material having a length of 10 mm, a width of 3 mm, and a thickness of 1 mm. One or both ends of the susceptor may be sharpened or pointed to facilitate insertion into the aerosol-forming substrate.

[0087] The aerosol generating article 10 has a proximal or oral end 70, which the user inserts into their mouth during use, and the distal end 80 is located on the opposite end of the aerosol generating article 10 from the oral end 70. The assembled aerosol generating article 10 has a total length of approximately 47 mm to 53 mm and a diameter of approximately 7.2 mm.

[0088] During use, air is drawn by the user through the aerosol generating article from the distal end 80 to the oral end 70. The distal end 80 of the aerosol generating article may also be described as the upstream end of the aerosol generating article 10, and the oral end 70 of the aerosol generating article 10 may also be described as the downstream end of the aerosol generating article 10. An element of the aerosol generating article 10 located between the oral end 70 and the distal end 80 may be described as being upstream of the oral end 70, or, alternatively, downstream of the distal end 80.

[0089] The plug element 90 is located at the most distal or upstream end 80 of the aerosol generating article 10. In Figure 1, the plug element is shown as a hollow tube, for example, a hollow cellulose acetate tube. The inner diameter of the hollow tube is the same as, or slightly smaller than, the width of the susceptor 25 to prevent the susceptor from detaching from the distal end of the aerosol forming substrate 20.

[0090] The aerosol-forming substrate 20 is located immediately downstream of the plug element 90 in the aerosol-generating article 10. In Figure 1, the aerosol-forming substrate 20 includes an assembly of crumpled and homogenized tobacco material sheets surrounded by a wrapper. The crumpled sheets of homogenized tobacco material contain glycerin as an aerosol-forming agent.

[0091] The support element 30 is located immediately downstream of the aerosol-forming substrate 20 and is adjacent to the aerosol-forming substrate 20. In Figure 1, the support element 30 is a hollow cellulose acetate tube. The support element 30 positions the aerosol-forming substrate 20 within the aerosol-generating article 10. In this way, the support element 30 helps prevent the aerosol-forming substrate 20 from being pushed downstream toward the aerosol cooling element 40 within the aerosol-generating article 10, for example, when inserting the article into the device. The support element 30 also acts as a spacer to separate the aerosol cooling element 40 of the aerosol-generating article 10 from the aerosol-forming substrate 20.

[0092] The aerosol cooling element 40 is located immediately downstream of the support element 30 and is adjacent to the support element 30. During use, volatile substances released from the aerosol-forming substrate 20 pass along the aerosol cooling element 40 toward the mouth end 70 of the aerosol-generating article 10. The volatile substances may cool within the aerosol cooling element 40 to form an aerosol that the user inhales. In Figure 1, the aerosol cooling element includes an assembly of crimped sheets of polylactic acid surrounded by a wrapper 90. The assembly of crimped sheets of polylactic acid defines multiple longitudinal paths extending along the length of the aerosol cooling element 40.

[0093] The mouthpiece 50 is located immediately downstream of the aerosol cooling element 40 and is adjacent to the aerosol cooling element 40. In Figure 1, the mouthpiece 50 contains a conventional cellulose acetate tow filter with low filtration efficiency.

[0094] To assemble the aerosol-generating article 10, the five cylindrical elements described above are aligned and tightly wrapped within the outer wrapper 60. In Figure 1, the outer wrapper is conventional cigarette paper.

[0095] Once the article is manufactured, four elements excluding the plug element 90 can be assembled. Next, the susceptor 25 is inserted into the distal end 80 of the assembly so as to penetrate the aerosol-forming substrate 20. Then the plug element 80 is aligned with the assembly, and then the five elements are wrapped in the wrapper 60 to form a complete aerosol-generating article 10. Alternatively, the susceptor 25 is inserted into the aerosol-forming substrate 20 before the multiple elements are assembled to form a rod.

[0096] The aerosol generating article 10 in Figure 1 is designed to engage with an electrically operated aerosol generating device, which includes an induction coil (or inductor) for smoking or consumption by the user.

[0097] Figure 2 illustrates an aerosol generating article 1 comprising six elements, where the same or similar elements are referred to by the same reference numbers. The plug element 91, aerosol forming substrate 20, support element in the form of a hollow cellulose acetate tube 30, aerosol cooling element 40, mouthpiece filter 50, and cardboard tube 56 are arranged in a continuous and coaxial manner and assembled from cigarette paper and chipping paper (not shown) to form a rod. The cardboard tube 56 is located at the mouth end 70 of the aerosol generating article 1, and the plug element 91 is located at the distal end 80 of the aerosol generating article 1.

[0098] When assembled, the rod has, for example, a length of 45 mm and an outer diameter of approximately 7.2 mm.

[0099] The plug element 91 is a porous plug, for example, a plug made of a heat-resistant material with open pores. The plug element has a length 95 of 3 to 5 mm.

[0100] The aerosol-forming substrate 20 may contain a bundle of crumpled cast-leaf tobacco wrapped in filter paper (not shown) to form a plug. The cast-leaf tobacco contains additives including glycerin as an aerosol-forming additive. The length 25 of the aerosol-forming substrate is 12 millimeters. The length of the susceptor 25 is approximately 10 mm, and it is pointed at its proximal end.

[0101] The hollow acetate tube 30 is located immediately downstream of the aerosol-forming substrate 20 and is adjacent to the aerosol-forming substrate 20. The length 35 of the acetate tube 30 is 8 mm.

[0102] The aerosol cooling element 40 has a length 45 of 10 mm to 13 mm and an outer diameter of approximately 7.12 mm. Preferably, the aerosol cooling element 40 is formed from a sheet of polylactic acid having a thickness of 50 mm ± 2 mm. The polylactic acid sheet is crimped and assembled to define multiple channels extending along the length of the aerosol cooling element 40. The total surface area of ​​the aerosol cooling element may be 300 square millimeters to 1000 square millimeters per 1 mm of length of the aerosol cooling element 40, or approximately 10 square millimeters to 100 square millimeters per 1 mg of weight of the aerosol cooling element 40.

[0103] The length 45 of the aerosol cooling element 40 is 5mm to 8mm shorter than that of conventional aerosol cooling elements in aerosol generating articles with a standard length of 45mm. The length of conventional aerosol cooling elements in such standard-length aerosol generating articles, particularly those made of polylactic acid sheets, is 18mm.

[0104] The mouthpiece filter 50, which is positioned downstream of the aerosol cooling element 40, may be a conventional mouthpiece filter made of cellulose acetate and has a length 55 of 7 millimeters.

[0105] The cardboard tube 56 is the most downstream element of the aerosol generating article 1 and also has a length of 3 to 5 millimeters 57. The cardboard tube, together with the plug element 80, compensates for the shorter aerosol cooling element 50 so that the total length of the aerosol generating article is 45 mm. The cardboard tube 56 also provides a recessed mouth end 70 of the aerosol generating article, mimicking the use of conventional cigarettes which have a recessed mouth end.

[0106] The shortened length of the aerosol cooling element 40 can compensate for the additional length 95 of the plug element 91 alone. A cardboard tube 56 may be provided as needed.

[0107] In Figure 3, the plug element 92 has a recess 920 with an open end facing the aerosol-forming substrate 20. The recess 920 is dome-shaped and has a maximum depth 921 which is 25 to 50 percent of the length 95 of the plug element. If the plug element has a length 95 of 5 mm, the depth 921 of the recess 920 is approximately 1 mm to 2.5 mm. The material of the plug element 92 is a heat-resistant material that can withstand temperatures of approximately 350°C. The plug element is preferably porous, allowing air to pass through the plug element 92.

[0108] Figure 4 illustrates an embodiment of a plug element 93 having an opening 930 positioned longitudinally within the plug element for air to pass through. The material of the plug element may also be airtight in some ways. The opening 930 has an irregular star-shaped cross-section, which can serve a marking purpose and may enhance the appearance of the aerosol-generating article.

Claims

1. An aerosol generating article comprising a plurality of elements assembled in the form of a rod having a mouth end and a distal end located upstream from the mouth end, wherein the plurality of elements are An aerosol-forming substrate having elongated susceptors arranged along its long axis, wherein the elongated susceptors have a length of 6 mm to 12 mm, and the elongated susceptors are in the form of strips or blades having a rectangular shape with a width of 2 mm to 8 mm and a thickness of 0.03 mm to 0.15 mm, A plug element positioned upstream of and adjacent to the aerosol-forming substrate and the elongated susceptor within the rod, having a length of 4 to 8 millimeters along the longitudinal axis of the aerosol-generating article, having an opening positioned in the longitudinal direction to allow air to pass through the plug element, and being formed from a polymer material that is impermeable to air, and Equipped with, The aerosol generating article has a total length of 40 mm to 55 mm and an outer diameter of 6 mm to 8 mm. Aerosol-generating items.

2. The aerosol generating article according to claim 1, wherein the plug element prevents displacement or deformation of the elongated susceptor during handling or transport of the aerosol generating article.

3. The aerosol generating article according to claim 1 or 2, wherein the plug element prevents the elongated susceptor from falling off the aerosol generating article.

4. The aerosol generating article according to any one of claims 1 to 3, wherein the plug element is airtight.

5. The aerosol generating article according to any one of claims 1 to 4, wherein the plug element is made of a heat-resistant material.

6. The aerosol generating article according to any one of claims 1 to 5, wherein the plug element is a separate element.

7. The aerosol generating article according to any one of claims 1 to 6, wherein the plug element has a length of 4 mm to 5 mm.

8. The aerosol generating article according to any one of claims 1 to 7, wherein the elongated susceptor has the same length as the aerosol-forming substrate.

9. The aerosol generating article according to any one of claims 1 to 8, further comprising a mouthpiece element located at the mouth end of the aerosol generating article, wherein the mouthpiece element comprises at least one filter segment.

10. The aerosol generating article according to any one of claims 1 to 9, wherein the aerosol generating article has a total length of 45 millimeters.

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