Aerosol generating article comprising a tubular element having integrated first and second tubular parts

Abstract

As an aerosol generating article (1), the article comprises a substrate element (2) including an aerosol generating substrate; and a tubular element (12) including an integral first (14) and second (16) tubular portion, wherein the first tubular portion and the second tubular portion each constitute at least 10% of the length of the tubular element; the first tubular portion has a first inner diameter (D1int) and the second tubular portion has a second inner diameter (D2int); the first inner diameter is different from the second inner diameter; and the second inner diameter is larger than the first inner diameter; the first tubular portion includes an inner tube segment (15) and a first portion of an outer tube segment (17) arranged around the inner tube segment, and the second tubular portion includes a second portion of an outer tube segment extending beyond the end of the inner tube segment in the longitudinal direction of the tubular element, wherein the first inner diameter is the inner diameter of the inner tube segment and the second inner diameter is the inner diameter of the second portion of the outer tube segment; And the outer tube segment contains one or more layers of web material, and the web material is wrapped parallel to the inner tube segment.

Description

Technology Field

[0001] The present disclosure relates to an aerosol generating article comprising, for example, an aerosol generating material for generating an inhalable aerosol upon heating. The present disclosure also relates to a method for manufacturing a tubular element for an aerosol generating article. Background Technology

[0002] Aerosol generating articles are known in the art in which an aerosol generating substrate, such as a tobacco-containing substrate, is heated without combustion. Typically, in such heated aerosol generating articles, an aerosol is generated by heat transfer from a heat source to a physically separate aerosol generating substrate or material, which may be located in contact with the heat source, inside the heat source, around the heat source, or downstream of the heat source. During use of the aerosol generating article, volatile compounds are released from the aerosol generating substrate by heat transfer from the heat source and entrained in the air drawn through the aerosol generating article. As the released compounds cool, they condense to form an aerosol.

[0003] A number of aerosol generating devices for consuming heated aerosol generating articles are known in the art. Such devices include, for example, electric heating aerosol generating devices in which aerosols are generated by heat transfer from one or more electric heater elements of the aerosol generating device to an aerosol generating substrate of the heated aerosol generating article. For example, electric heating aerosol generating devices have been proposed that include internal resistance heater blades adapted to be inserted into an aerosol generating substrate. As an alternative, an induction-heatable aerosol generating article includes susceptor elements arranged within an aerosol generating substrate that can be heated by an alternating magnetic field provided by the aerosol generating device.

[0004] Heated aerosol generating articles are typically cigarette-shaped and comprise a plurality of elements or plugs. For example, such articles typically comprise a substrate plug comprising an aerosol generating substrate, a tubular plug downstream of the substrate plug, and a mouthpiece filter plug at the mouth end of the article. The tubular plug has an internal cavity or hollow core that defines an airflow path. It is known to have two tubular plugs: a first tubular plug that functions as a spacer between the substrate plug and other components of the aerosol generating article; and a separate second tubular plug that functions as an air cooler to cool air as it passes through the aerosol generating article and helps to form an aerosol. The second tubular plug generally borders the first tubular plug.

[0005] Aerosol generating articles in the form of inhaler articles, such as dry powder inhalers, are known in the art. Some dry powder inhalers have components for storing dry powder, such as capsules. The capsule may be activated by being penetrated by a separate penetration element, such as a penetration element of a holder. Once the capsule is activated, the consumer may generate an airflow through the inhaler by inhaling the mouth end of the inhaler. Each airflow from each inhalation can transport a portion of the dry powder from the capsule to the user's lungs. Aerosol generating articles can generate aerosols without heating.

[0006] Aerosol generating articles, such as dry powder inhalers, generally include a retaining plug or element having a cavity or hollow core that helps define an airflow path and maintain or otherwise resist the movement of the capsule so that the capsule can be easily penetrated. Such retaining plugs are typically formed of two tubular plugs: a first tubular plug extending across the interior of the aerosol generating article and fixed inside the aerosol generating article; and a second separate, smaller tubular plug fixed to the first tubular plug on the side of the first tubular plug facing the capsule. The smaller diameter of the second tubular plug provides a well or gutter between its outer tubular surface and the inner surface of the aerosol generating article collecting the dry powder, and once the capsule is penetrated, for example, if the article is inclined, reduces the likelihood of the dry powder leaking out of the article.

[0007] Manufacturing and assembling the first and second tubular plugs of both heated aerosol generating articles and non-heated aerosol generating articles, such as dry powder inhalers, can be difficult because airflow is restricted within their internal cavities. The ability of the first and second tubular plugs to perform their respective functions depends on how accurately they are positioned and aligned. Since the quality and consistency of the consumer experience can depend on the internal air path through the aerosol generating article, it is important that the first and second tubular plugs are adjacent and concentric. Additionally, the aerosol generating article may be prone to breakage at the interface between the first and second tubular plugs when force is applied to the aerosol generating article, for example, during insertion of the aerosol generating article into an aerosol generating device.

[0008] It would be desirable to provide an aerosol-generating article that is easier to manufacture and reduces the need for precise positioning and alignment of tubular plugs or elements. It would also be desirable to provide an aerosol-generating article that is less sensitive to breakage at the interface between the first and second tubular plugs.

[0009] According to one example of the present disclosure, an aerosol generating article is provided. The aerosol generating article may include a substrate element including an aerosol generating substrate. The aerosol generating article may include a tubular element. The tubular element may include a first tubular portion. The tubular element may include a second tubular portion. The first and second tubular portions may be integral. The first tubular portion may constitute at least 10% of the length of the tubular element. The second tubular portion may constitute at least 10% of the length of the tubular element.

[0010] In one example, the first tubular part may have a first inner diameter. The second tubular part may have a second inner diameter. The first inner diameter may be different from the second inner diameter.

[0011] In another example, the first tubular part may have a first outer diameter. The second tubular part may have a second outer diameter. The first outer diameter may be different from the second outer diameter.

[0012] According to one example of the present disclosure, an aerosol generating article is provided comprising: a substrate element comprising an aerosol generating substrate; and a tubular element comprising an integral first and second tubular portion. The first tubular portion and the second tubular portion each constitute at least 10% of the length of the tubular element. The first tubular portion has a first inner diameter, and the second tubular portion has a second inner diameter, and the first inner diameter is different from the second inner diameter. Alternatively or additionally, the first tubular portion has a first outer diameter, and the second tubular portion has a second outer diameter, and the first outer diameter is different from the second outer diameter.

[0013] The term “aerosol generating article” is used herein to refer to an article in which an inhalable aerosol is generated from an aerosol generating substrate and delivered to a consumer. As used herein, the term “aerosol generating substrate” refers to a substrate in which an aerosol may be formed or generated. For example, an aerosol generating substrate may generate an aerosol by releasing volatile compounds upon heating. Alternatively, an aerosol generating substrate may comprise particles that can be entrained by an airflow to generate an aerosol.

[0014] As used herein, the term “tubular element” refers to a generally hollow, elongated element that defines a lumen or airflow passage along its longitudinal axis. In particular, the term “tubular” will be used to refer to a tubular element having a substantially cylindrical cross section and having an internal cavity that defines at least one airflow conduit establishing unimpeded fluid communication between the upstream end of the tubular element and the downstream end of the tubular element. However, it will be understood that alternative geometries of the tubular element (e.g., alternative cross-sectional shapes) may be possible. The tubular element is an individual, distinct component of the aerosol generating article.

[0015] As used herein with respect to the first and second tubular parts of the tubular element, the term “integral” is intended to mean that the first and second tubular parts each form a part of the tubular element rather than being separate components. Accordingly, the tubular element comprising the first and second tubular parts is a single component of the aerosol generating article. The first and second tubular parts cannot be separated without applying a force that damages or destroys the tubular element.

[0016] With respect to an aerosol generating article, the term "length" refers to the dimensions of a component of the aerosol generating article along the longitudinal direction of the aerosol generating article. The longitudinal direction of the aerosol generating article refers to the direction corresponding to the main longitudinal axis of the aerosol generating article extending between the upstream and downstream ends of the aerosol generating article. As used herein, the terms "upstream" and "downstream" describe the relative positions of an element of the aerosol generating article, or a part of an element, with respect to the direction in which the aerosol is transported through the aerosol generating article during use.

[0017] By providing a tubular element having integral first and second tubular parts, the first and second tubular parts advantageously each form part of the tubular element rather than separate components. This helps alleviate any difficulties in positioning the first and second tubular parts relative to each other during the assembly of an aerosol generating article compared to forming the first and second tubular parts as separate elements. Since the tubular element having integral first and second tubular parts is already assembled and automatically achieves the benefits of this configuration, there is no need to precisely interlock the first and second tubular parts during the assembly of the aerosol generating article. The integral nature of the tubular element also helps ensure that the first and second tubular parts are axially aligned. This helps ensure smooth airflow through the tubular element and provides a consistent consumer experience.

[0018] In addition, providing a tubular element having integrated first and second tubular parts helps to reinforce the tubular element and helps to reduce the risk of damage or breakage of the tubular element at the interface between the first and second tubular parts when force is applied to the aerosol generating article, for example, during insertion of the aerosol generating article into an aerosol generating device.

[0019] The first tubular part and the second tubular part may each constitute at least 20% of the length of the tubular element, preferably at least 30% of the length of the tubular element, and more preferably at least 40% of the length of the tubular element. In a preferred example, the first tubular part and the second tubular part may each constitute about 50% of the length of the tubular element.

[0020] The first tubular portion may have a first inner diameter that is uniform or constant over the length of the first tubular portion. The second tubular portion may have a second inner diameter that is uniform or constant over the length of the second tubular portion.

[0021] The first tubular portion may have a first outer diameter that is uniform or constant over the length of the first tubular portion. The second tubular portion may have a second outer diameter that is uniform and / or constant over the length of the second tubular portion.

[0022] The difference in inner or outer diameter may be formed by a step on the inner or outer surface of the tubular element. The difference between the first inner diameter and the second inner diameter may be formed by a step on the inner surface of the tubular element. The difference between the first outer diameter and the second outer diameter may be formed by a step on the outer surface of the tubular element.

[0023] The difference between the inner or outer diameter is at least 0.2 mm, optionally at least 0.5 mm, optionally at least 0.7 mm, optionally at least 1 mm, optionally at least 1.5 mm, optionally at least 2 mm, and more optionally at least 2.5 mm. The difference between the inner or outer diameter may be about 0.2 mm to 2.5 mm, optionally 0.5 mm to 2.0 mm, optionally 0.7 mm to 2.0 mm, and optionally 1 mm to 2 mm.

[0024] In one exemplary aerosol generating article, the first and second tubular portions may each have different first and second inner diameters. The second tubular portion may be arranged downstream of the first tubular portion.

[0025] The second inner diameter may be larger than the first inner diameter. The second inner diameter may be at least 1 mm larger than the first inner diameter. Optionally, the second inner diameter may be at least 1.2 mm larger than the first inner diameter. Optionally, the second inner diameter may be at least 1.4 mm larger than the first inner diameter. Optionally, the second inner diameter may be at least 1.6 mm larger than the first inner diameter. Optionally, the second inner diameter may be at least 1.8 mm larger than the first inner diameter. Optionally, the second inner diameter may be at least 2.0 mm larger than the first inner diameter.

[0026] The difference between the first and second inner diameters may be about 0.5 to about 3.0 mm, optionally about 1 mm to about 2.5 mm, and more optionally about 1.5 mm to about 2.0 mm. In a preferred example, the difference between the first and second inner diameters may be about 1.7 mm.

[0027] The ratio of the second inner diameter to the first inner diameter may be 1.2 to 2.5, optionally 1.2 to 2.0, more optionally 1.3 to 1.7, and more optionally 1.4 to 1.6. In one example, the ratio of the second inner diameter to the first inner diameter may be about 1.4. In another example, the ratio of the second inner diameter to the first inner diameter may be about 2.0 to about 2.5.

[0028] The first tubular portion may include an inner tube segment. The first tubular portion may include a first portion of an outer tube segment. The first portion of the outer tube segment may be arranged around the inner tube segment. The second tubular portion may include a second portion of the outer tube segment. The second portion of the outer tube segment may extend past the end of the inner tube segment in the longitudinal direction of the tubular element. The first inner diameter may be the inner diameter of the inner tube segment. The second inner diameter may be the inner diameter of the second portion of the outer tube segment.

[0029] Advantageously, by forming tubular elements from inner and outer tube segments, it is possible to use different materials to form each of the inner and outer tube segments. In particular, different materials may be selected to form the inner and outer tube segments according to the specific physical requirements of each of the inner and outer tube segments.

[0030] The outer tube segment may overlap with the inner tube segment. The outer tube segment may overlap with at least 50% of the length of the inner tube segment, preferably at least 60% of the length of the inner tube segment, more preferably at least 70% of the length of the inner tube segment, even more preferably at least 80% of the length of the inner tube segment, and even more preferably at least 90% of the length of the inner tube segment. The outer tube segment may overlap with the entire length of the inner tube segment.

[0031] The inner tube segment may include a plurality of layers of the first web material. The inner tube segment may include 1 to 20 layers of the first web material. The inner tube segment may include a plurality of substantially continuous strips of the first web material.

[0032] The outer tube segment may include a plurality of layers of the first web material. The outer tube segment may include 1 to 20 layers of the first web material. The outer tube segment may include a plurality of substantially continuous strips of the first web material.

[0033] A substantially continuous strip may be wound spirally. As used herein, the terms “spirally wound” or “spiral winding” refer to a process of forming a tube by winding at least one substantially continuous strip of web material in a spiral or helical manner around a forming means, such as an elongated cylindrical mandrel. At least one strip of web material is fed to the mandrel such that the direction of inflow of at least one strip of web material forms an acute angle with the longitudinal axis of the mandrel.

[0034] The inner tube segment and the outer tube segment may comprise a substantially continuous strip wound in a plurality of spirals of the first web material.

[0035] The first web material may include any suitable web material. For example, the first web material may include one or more of paper, cardboard, acetate tow, or polylactic acid (PLA). In one example, the first web material may include a cellulose material such as paper or cardboard.

[0036] The width of the substantially continuous strip may be 10 mm to 50 mm. The width of the first web material may be 0.05 mm to 0.1 mm.

[0037] The outer tube segment may comprise one or more layers of the second web material. The second web material may be wrapped in parallel around the inner tube segment. As used herein, the term “wrapped in parallel” refers to a process of forming a tube by wrapping another element, e.g., the inner tube segment, within the web material such that the opposing side edges of the web material come together in a parallel manner.

[0038] The outer tube segment may include a plurality of layers of a second web material wrapped parallel to the inner tube segment. The outer tube segment may include 1 to 20 layers of the second web material.

[0039] The second web material may include any suitable web material. For example, the second web material may include one or more of paper, cardboard, acetate tow, or polylactic acid (PLA). In one example, the second web material may include a cellulose material such as paper or cardboard.

[0040] The thickness of the second web material may be 0.05 mm to 1.1 mm.

[0041] Tubular elements can be hollow. Tubular elements can be hollow along their entire length.

[0042] A first tubular portion of the tubular element may define a first internal cavity of the tubular element extending from an upstream end of the first tubular portion to a downstream end of the first tubular portion. The first internal diameter is the internal diameter of the first internal cavity. The first internal cavity may define at least a portion of the airflow path through the tubular element. The first internal cavity may be substantially empty to allow substantially unlimited airflow along the first internal cavity. The resistance to suction (RTD) of the first tubular portion may be substantially 0 mm H2O. Therefore, the first tubular portion does not substantially contribute to the total RTD of the aerosol-generating article. The first tubular portion of the tubular element may be configured to act as a spacer or support element for the aerosol-generating article.

[0043] A second tubular portion of the tubular element may define a second internal cavity of the tubular element extending from an upstream end of the second tubular portion to a downstream end of the second tubular portion. The second internal cavity may define at least a portion of the airflow path through the tubular element. The second internal cavity may be substantially empty to allow for substantially unlimited airflow along the second internal cavity. The RTD of the second tubular portion may be substantially 0 mm H2O. Therefore, the second tubular portion does not substantially contribute to the total RTD of the aerosol generating article. The second tubular portion of the tubular element may be configured to function as an aerosol cooling element for the aerosol generating article.

[0044] The tubular element may be aligned with the substrate element and arranged downstream of the substrate element. In a preferred example, the tubular element is located immediately downstream of the substrate element. The upstream end of the tubular element may border the downstream end of the substrate element.

[0045] The tubular element preferably has an outer diameter approximately equal to the outer diameter of the base element and the outer diameter of the aerosol generating article.

[0046] The tubular 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 example, the tubular element has an outer diameter of 7.1 mm + / - 10%.

[0047] The first tubular portion of the tubular element may have an inner diameter of at least about 2.5 mm, preferably at least about 3.0 mm, more preferably at least about 3.5 mm. Alternatively or additionally, the first tubular portion of the tubular element may have an inner diameter of less than about 4.0 mm, preferably less than about 3.5 mm or less than about 3.0 mm.

[0048] The first tubular portion of the tubular element may have an inner diameter of about 2.0 mm to about 4.0 mm, preferably about 2.5 mm to about 3.5 mm, more preferably about 3.0 mm to 3.5 mm. In a preferred example, the first tubular portion of the tubular element may have an inner diameter of about 3.3 mm.

[0049] The periphery wall surface of the first tubular portion may have a thickness of at least about 1 mm, preferably at least about 1.5 mm, or at least about 2 mm. Alternatively or additionally, the periphery wall surface of the first tubular portion may have a thickness of less than about 3 mm, preferably less than about 2.5 mm or less than about 2 mm.

[0050] The peripheral wall surface of the first tubular portion may have a thickness of about 1 mm to about 3 mm, preferably about 1.5 mm to about 2.5 mm, and more preferably about 1.5 mm to 2.0 mm. In a preferred example, the peripheral wall surface of the first tubular portion may have a thickness of about 1.9 mm.

[0051] The first tubular portion of the tubular element may have a length of at least about 5 mm, preferably at least about 6 mm, more preferably at least about 7 mm. The first tubular portion of the tubular element may have a length of less than about 15 mm, preferably less than about 12 mm, more preferably less than about 10 mm.

[0052] The first tubular portion of the tubular element may have a length of about 5 mm to about 15 mm, preferably about 6 mm to 12 mm, more preferably about 7 mm to 10 mm. In a preferred example, the first tubular portion of the tubular element may have a length of about 8 mm or about 9 mm.

[0053] The second tubular portion of the tubular element may have an inner diameter of at least about 4.0 mm, preferably at least about 4.5 mm, more preferably at least about 5.0 mm. Alternatively or additionally, the second tubular portion of the tubular element may have an inner diameter of less than about 6.0 mm, preferably less than about 5.5 mm or less than about 5.0 mm.

[0054] The second tubular portion of the tubular element may have an inner diameter of about 4.0 mm to about 6.0 mm, preferably about 4.5 mm to about 6.0 mm, and more preferably about 4.5 mm to 5.5 mm. In a preferred example, the second tubular portion of the tubular element may have an inner diameter of about 5.0 mm.

[0055] The peripheral wall surface of the second tubular portion may have a thickness of at least about 0.3 mm, preferably at least about 0.6 mm, more preferably at least about 0.9 mm. Alternatively or additionally, the peripheral wall surface of the second tubular portion may have a thickness of less than about 2.5 mm, preferably less than about 2.0 mm, more preferably less than about 1.5 mm.

[0056] The peripheral wall surface of the second tubular portion may have a thickness of about 0.3 mm to 2.5 mm, preferably about 0.6 mm to 2.0 mm, and more preferably about 0.9 mm to 1.5 mm. In a preferred example, the peripheral wall surface of the second tubular portion may have a thickness of about 1.05 mm.

[0057] The second tubular portion of the tubular element may have a length of at least about 5 mm, preferably at least about 6 mm, more preferably at least about 7 mm. The second tubular portion of the tubular element may have a length of less than about 15 mm, more preferably less than about 12 mm, more preferably less than about 10 mm.

[0058] The second tubular portion of the tubular element may have a length of about 5 mm to about 15 mm, preferably about 6 mm to 12 mm, more preferably about 7 mm to 10 mm. In a preferred example, the second tubular portion of the tubular element may have a length of about 8 mm.

[0059] The aerosol generating article may further include a ventilation zone provided at a location along the second tubular portion. The inventors have discovered that satisfactory cooling of the stream of aerosol generated when the aerosol generating material is heated and the aerosol is drawn through the tubular element can be achieved by providing a ventilation zone at a location along the second tubular portion.

[0060] The ventilation zone may include a plurality of ventilation holes or perforations through the surrounding wall surface of the second tubular portion. Preferably, the ventilation zone includes at least one column of circumferential perforations. In some examples, the ventilation zone may include two columns of circumferential perforations. Preferably, each column of circumferential perforations includes 8 to 30 perforations.

[0061] Aerosol-generating products can have a ventilation level of at least about 5%.

[0062] The term "ventilation level" is used herein to denote the volume ratio between the airflow entering the aerosol-generating product through the ventilation zone (ventilation airflow) and the sum of the aerosol airflow and the ventilation airflow. The higher the ventilation level, the higher the dilution of the aerosol flow delivered to the consumer.

[0063] The aerosol-generating article may have a ventilation level of at least about 10%, preferably at least about 15%, and more preferably about 20%. The aerosol-generating article may have a ventilation level of less than about 60%, preferably less than about 45%, and more preferably less than about 40%. In a preferred example, the aerosol-generating article has a ventilation level of about 25% or 30%.

[0064] The aerosol generating article may include multiple elements assembled in a rod shape.

[0065] The aerosol generating article may include a downstream section located downstream of a substrate element. The downstream section may include one or more downstream elements. The downstream section may include a tubular element. The downstream section may include a mouthpiece element.

[0066] The mouthpiece element may be aligned with the tubular element and arranged downstream of the tubular element. In a preferred example, the mouthpiece element is located immediately downstream of the tubular element. The upstream end of the mouthpiece element may border the downstream end of the tubular element.

[0067] The mouthpiece element is preferably located at the downstream end of the aerosol-generating article or at the end of the mouthpiece. The mouthpiece element comprises at least one mouthpiece filter segment of a fibrous filter material for filtering aerosols 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 of cellulose acetate tow.

[0068] Preferably, the mouthpiece element has low particulate filtration efficiency.

[0069] Preferably, the mouthpiece element is surrounded by a plug wrap. Preferably, the mouthpiece element is not ventilated so that air does not enter the aerosol-generating article along the mouthpiece element.

[0070] The mouthpiece element is preferably connected to one or more adjacent upstream components of the aerosol generating article by a tipping wrapper.

[0071] The mouthpiece element preferably has an outer diameter approximately equal to the outer diameter of the aerosol generating article. The mouthpiece element may have an outer diameter of about 5 mm to about 10 mm, or about 6 mm to about 8 mm. In a preferred example, the mouthpiece element has an outer diameter of about 7.1 mm.

[0072] The mouthpiece element preferably has a length of at least about 5 mm, preferably at least about 8 mm, and more preferably at least about 10 mm. Alternatively or additionally, the mouthpiece element preferably has a length of less than about 25 mm, preferably less than about 20 mm, and more preferably less than about 15 mm.

[0073] The mouthpiece element may have a length of about 5 mm to about 25 mm, or about 8 mm to about 20 mm, or about 10 mm to about 15 mm. In a preferred example, the mouthpiece element has a length of about 12 mm.

[0074] The inscription element may be aligned with the tubular element and arranged upstream of the tubular element. The inscription element may border the tubular element. In a preferred example, the inscription element is located immediately upstream of the tubular element. The downstream end of the inscription element may border the upstream end of the tubular element.

[0075] Preferably, the substrate element is surrounded by a plug wrap.

[0076] The base element preferably has an outer diameter approximately equal to the outer diameter of the aerosol generating article. The base element may have an outer diameter of about 5 mm to about 10 mm, or about 6 mm to about 8 mm. In a preferred example, the base element has an outer diameter of about 7.1 mm.

[0077] The base element preferably has a length of at least about 5 mm, preferably at least about 8 mm, more preferably at least about 10 mm. Alternatively or additionally, the base element preferably has a length of less than about 25 mm, preferably less than about 20 mm, more preferably less than about 15 mm.

[0078] The substrate element may have a length of about 5 mm to about 25 mm, or about 8 mm to about 20 mm, or about 10 mm to about 15 mm. In a preferred example, the substrate element has a length of about 11 mm or about 12 mm.

[0079] As described above, the substrate element includes an aerosol generating substrate. The aerosol generating substrate may be a solid aerosol generating substrate.

[0080] The aerosol generating material preferably includes an aerosol forming agent.

[0081] The aerosol-forming agent may be any suitable known compound or mixture of compounds that facilitates the formation of a dense and stable aerosol upon use. The aerosol-forming agent may facilitate the aerosol having substantially resistance to thermal degradation at the temperature typically applied during use of the aerosol-generating article. For example, suitable aerosol-forming agents are polyhydric alcohols such as, for example, triethylene glycol, 1,3-butanediol, propylene glycol, and glycerin; esters of polyhydric alcohols such as, for example, glycerol mono-, di-, or triacetate; and aliphatic esters of mono-, di-, or polycarboxylic acids such as, for example, dimethyl dodecanedioate and dimethyl tetradecanedioate; and combinations thereof.

[0082] Preferably, the aerosol forming agent comprises one or more of glycerin and propylene glycol. The aerosol forming agent may consist of glycerin or propylene glycol or a combination of glycerin and propylene glycol.

[0083] The aerosol generating substrate may contain at least about 5% by weight, at least about 10% by weight, or at least about 12% by weight of an aerosol forming agent based on the dry weight of the aerosol generating substrate.

[0084] The aerosol generating substrate may contain an aerosol forming agent in an amount of about 30% by weight or less, about 25% by weight or less, or about 20% by weight or less based on the dry weight of the aerosol generating substrate.

[0085] The aerosol generating substrate may contain about 5% to about 30% by weight, about 5% to about 25% by weight, or about 5% to about 20% by weight of an aerosol forming agent based on the dry weight of the aerosol generating substrate.

[0086] The aerosol generating substrate may contain about 10% to about 30% by weight, about 10% to about 25% by weight, or about 10% to about 20% by weight of an aerosol forming agent based on the dry weight of the aerosol generating substrate.

[0087] The aerosol generating substrate may contain about 12% to about 30% by weight, about 12% to about 25% by weight, or about 12% to about 20% by weight of an aerosol forming agent based on the dry weight of the aerosol generating substrate.

[0088] The aerosol generating material may include multiple pieces of tobacco material. The aerosol generating material may include multiple pieces of homogenized tobacco material.

[0089] As used herein, the term "piece" refers to an element having a length substantially greater than its width and thickness.

[0090] As used herein, the term "homogenized tobacco material" is used to describe a material formed by aggregating particulate tobacco material.

[0091] Pieces of homogenized tobacco material can be formed into sheets of homogenized tobacco material by, for example, cutting or crushing. Pieces of homogenized tobacco material can be formed by other methods, for example, extrusion.

[0092] Pieces of tobacco material may have a width of at least about 0.3 mm, at least about 0.5 mm, or at least about 0.6 mm.

[0093] The pieces of tobacco material may have a width of about 2 mm or less, about 1.2 mm or less, or about 0.9 mm or less.

[0094] The pieces of tobacco material may have a width of about 0.3 mm to about 2 mm, about 0.3 mm to about 1.2 mm, or about 0.3 mm to about 0.9 mm.

[0095] The pieces of tobacco material may have a width of about 0.5 mm to about 2 mm, about 0.5 mm to about 1.2 mm, or about 0.5 mm to about 0.9 mm.

[0096] The pieces of tobacco material may have a width of about 0.6 mm to about 2 mm, about 0.6 mm to about 1.2 mm, or about 0.6 mm to about 0.9 mm.

[0097] Pieces of tobacco material can have a length of at least about 10 mm.

[0098] Pieces of tobacco material can have a length of about 40 mm or less.

[0099] Pieces of tobacco material can have a length of about 10 mm to about 40 mm.

[0100] Based on dry weight, at least about 20% by weight of a plurality of pieces of tobacco material may extend along the entire length of the aerosol generating substrate. Based on dry weight, at least about 20% by weight of a plurality of pieces of tobacco material may have a length substantially equal to the length of the aerosol generating substrate.

[0101] Based on dry weight, about 60% by weight or less of the number of pieces of tobacco material may extend along the entire length of the aerosol generating substrate. Based on dry weight, about 60% by weight or less of the number of pieces of tobacco material may have a length substantially equal to the length of the aerosol generating substrate.

[0102] About 20% to 60% by weight of a plurality of pieces of tobacco material on a dry weight basis may extend along the entire length of the aerosol generating substrate. About 20% to 60% by weight of a plurality of pieces of tobacco material on a dry weight basis may have a length substantially equal to the length of the aerosol generating substrate.

[0103] The size of the components of the aerosol generating substrate, such as multiple pieces of tobacco material, can play a role in the heat distribution within the aerosol generating substrate. Additionally, the size of the components of the aerosol generating substrate can play a role in the RTD of the article.

[0104] The aerosol generating material may include multiple pellets or granules of tobacco material. The aerosol generating material may include multiple pellets or granules of homogenized tobacco material.

[0105] The aerosol generating material may include one or more sheets of tobacco material.

[0106] The aerosol generating material may include one or more sheets of homogenized tobacco material.

[0107] One or more sheets of tobacco material may each individually have a thickness of at least about 100 µm, at least about 150 µm, or at least about 300 µm.

[0108] As used herein, individual thickness refers to the thickness of individual sheets of tobacco material, whereas combined thickness refers to the total thickness of all sheets of tobacco material constituting an aerosol generating substrate. For example, if the aerosol generating substrate is formed from two individual sheets of tobacco material, the combined thickness is the sum of the thicknesses of the two individual sheets of tobacco material or the measured thickness of the two sheets of tobacco material, wherein the two sheets of tobacco material are laminated onto the aerosol generating substrate.

[0109] One or more sheets of tobacco material may each have a thickness of about 600 µm or less, about 300 µm or less, or about 250 µm or less.

[0110] One or more sheets of tobacco material may each have a thickness of about 100 µm to about 600 µm, about 100 µm to about 300 µm, or about 100 µm to about 250 µm.

[0111] One or more sheets of tobacco material may each have a thickness of about 150 µm to about 600 µm, about 150 µm to about 300 µm, or about 150 µm to about 250 µm.

[0112] One or more sheets of tobacco material may each have a thickness of about 250 µm to about 600 µm, about 250 µm to about 300 µm, or about 250 µm to about 250 µm.

[0113] One or more sheets of tobacco material may each individually have a length substantially equal to the length of the aerosol generating material.

[0114] One or more sheets of tobacco material may be one or more of curls, folds, wrinkles, and fine wrinkles.

[0115] The compression, folding, creasing, or creasing of one or more sheets of tobacco material can cause one or more sheets of tobacco material to split and form pieces of tobacco material. For example, one or more sheets of tobacco material may be compressed to the extent that the integrity of one or more sheets of tobacco material is destroyed at multiple parallel ridges or wavy creases that cause separation of the material, thereby causing the formation of pieces of tobacco material.

[0116] The aerosol generating article may include a susceptor arranged within an aerosol generating substrate. The first element may include a susceptor arranged within an aerosol generating substrate.

[0117] As used herein, the term "susceptor" refers to a material capable of converting electromagnetic energy into heat. When placed in a fluctuating electromagnetic field, eddy currents induced within the susceptor cause the susceptor to heat up.

[0118] The susceptor is arranged in thermal contact with the aerosol generating substrate. Therefore, when the susceptor is heated, the aerosol generating substrate is heated by the susceptor to generate an aerosol. The susceptor can be arranged in direct physical contact with the aerosol generating substrate.

[0119] The susceptor can be an elongated susceptor.

[0120] As used herein, the term "slender" is used to describe a component of an aerosol-generating article having a length greater than its width and thickness.

[0121] The slender susceptor can be arranged substantially longitudinally within the aerosol generating substrate. That is, the longitudinal axis of the slender susceptor can be approximately parallel to the longitudinal axis of the aerosol generating substrate. For example, the longitudinal axis of the slender susceptor can be within ±10 degrees of the longitudinal axis of the aerosol generating substrate. The slender susceptor is located at a radial center position within the aerosol generating substrate and can extend along the longitudinal axis of the aerosol generating substrate.

[0122] The susceptor can be extended from the downstream end of the aerosol generating device toward the upstream end of the aerosol generating device.

[0123] The susceptor can be extended from the upstream end of the aerosol generating device toward the downstream end of the aerosol generating device.

[0124] The susceptor can extend from the upstream end of the aerosol generating device to the downstream end of the aerosol generating device. That is, the susceptor can extend along the entire length of the aerosol generating device.

[0125] The length of the susceptor can be substantially the same as the length of the aerosol generating device.

[0126] The susceptor can be partially extended along the length of the aerosol generating device.

[0127] The susceptor can be spaced apart from the downstream end of the aerosol generating device.

[0128] The susceptor can be spaced apart from the upstream end of the aerosol generating device.

[0129] The susceptor can be spaced apart from the downstream and upstream ends of the aerosol generating device.

[0130] The length of the susceptor may be less than the length of the aerosol generating device.

[0131] The susceptor can be entirely encased within the aerosol generating substrate. In other words, the aerosol generating substrate can completely surround the susceptor.

[0132] The susceptor can be in the form of a pin, rod, strip, or blade.

[0133] The susceptor may have a length of at least about 5 mm, at least about 6 mm, or at least about 8 mm. The susceptor may have a length of about 15 mm or less, about 12 mm or less, or about 10 mm or less.

[0134] The susceptor may have a length of about 5 mm to about 15 mm, about 5 mm to about 12 mm, or about 5 mm to about 10 mm.

[0135] The susceptor may have a length of about 6 mm to about 15 mm, about 6 mm to about 12 mm, or about 6 mm to about 10 mm.

[0136] The susceptor may have a length of about 8 mm to about 15 mm, about 8 mm to about 12 mm, or about 8 mm to about 10 mm.

[0137] The susceptor can have a width of at least about 1 mm.

[0138] The susceptor can have a width of about 5 mm or less.

[0139] The susceptor can have a width of about 1 mm to about 5 mm.

[0140] The susceptor may have a thickness of at least about 0.01 mm, or at least about 0.5 mm.

[0141] The susceptor may have a thickness of about 2 mm or less, about 500 µm or less, or about 100 µm or less.

[0142] The susceptor may have a thickness of about 10 µm to about 2 mm, about 10 µm to about 500 µm, or about 10 µm to about 100 µm.

[0143] The susceptor can have a thickness of about 0.5 mm to about 2 mm.

[0144] The susceptor can have a practically circular cross-section.

[0145] A susceptor can have a substantially constant cross-section along its length.

[0146] If the susceptor has the form of a strip or a blade, the strip or blade may have a rectangular shape with a width of about 2 mm to about 8 mm, or about 3 mm to about 5 mm. For example, a strip-shaped susceptor with a blade may have a width of about 4 mm.

[0147] If the susceptor has the form of a strip or blade, the strip or blade may have a rectangular shape and a thickness of about 0.03 mm to about 0.15 mm, or about 0.05 mm to about 0.09 mm. For example, a susceptor in the form of a strip or blade may have a thickness of about 0.07 mm or about 0.06 mm.

[0148] The susceptor may be formed of any material that can be induced heated to a temperature sufficient to generate an aerosol from an aerosol generating substrate. For example, the susceptor may comprise metal or carbon.

[0149] The susceptor may comprise or be made of a ferromagnetic material, for example, a ferromagnetic alloy, ferritic iron, ferromagnetic steel, or stainless steel. A suitable susceptor may be aluminum or may comprise it. The susceptor may be formed of 400 series stainless steel, for example, grade 410, or grade 420 or grade 430 stainless steel. Different materials will lose different amounts of energy when placed in an electromagnetic field having similar values ​​of frequency and magnetic field strength.

[0150] Therefore, parameters of the susceptor, such as material type, length, width, and thickness, can all be modified to provide the desired power dissipation within a known electromagnetic field. The susceptor is 250 It can be heated to a temperature exceeding .

[0151] A suitable susceptor may comprise a nonmetal core having a metal layer disposed on a nonmetal core, for example, a metal track formed on the surface of a ceramic core. The susceptor may have a protective outer layer, for example, a protective ceramic layer or a protective glass layer encapsulating the susceptor. The susceptor may comprise a protective coating layer formed by glass, ceramic, or an inert metal, formed across the core of the susceptor material.

[0152] The susceptor may be a multimaterial susceptor and may include a first susceptor material and a second susceptor material.

[0153] The aerosol-generating article may additionally include an upstream section located upstream of the base element. The upstream section may include one or more upstream elements. In some examples, the upstream section may include an upstream element arranged immediately upstream of the base element. The upstream element may be arranged in alignment with the base element. The downstream end of the upstream element may border the upstream end of the base element. The upstream element may help reduce the risk of injury to consumers coming into contact with the base element or the high-temperature susceptor.

[0154] The upstream element preferably has an outer diameter approximately equal to the outer diameter of the base element and the outer diameter of the aerosol-generating article. The upstream element may have an outer diameter of about 5 mm to about 10 mm, or about 6 mm to about 8 mm. In a preferred example, the upstream element has an outer diameter of about 7.1 mm.

[0155] The upstream element preferably has a length of at least about 2 mm, preferably at least about 3 mm, and more preferably at least about 4 mm. Alternatively or additionally, the upstream element preferably has a length of less than about 10 mm, preferably less than about 8 mm, and more preferably less than about 6 mm.

[0156] The upstream element may have a length of about 2 mm to about 10 mm, or about 3 mm to about 8 mm, or about 4 mm to about 6 mm. In a preferred example, the upstream element may have a length of about 5 mm.

[0157] The aerosol generating article may further include a wrapper that surrounds at least one component of the aerosol generating article. The wrapper may surround a tubular element and at least one other component of the aerosol generating article. The wrapper may surround at least a portion of the tubular element and a component of the aerosol generating article upstream of the tubular element. The wrapper may surround at least a portion of the tubular element and a component of the aerosol generating article downstream of the tubular element.

[0158] In one example, the wrapper can surround an upstream element, a substrate element, and a tubular element to form a wrapped subassembly. The wrapped subassembly can be joined to a mouthpiece element by tipping paper. The tipping paper can surround the mouthpiece element and the downstream portion of the wrapped subassembly.

[0159] In another example, the wrapper may surround all components of the aerosol generating article. The wrapper may extend along the entire length of the aerosol generating article, that is, from the upstream end of the aerosol generating article to the downstream end of the aerosol generating article.

[0160] The wrapper may be an outer wrapper. The wrapper may be an outermost wrapper. The outer surface of the wrapper may form the outer surface of an aerosol-generating article. The wrapper may be porous, or may be equipped with a ventilation means, particularly in an area of ​​a ventilation zone or on top thereof.

[0161] According to one example of the present disclosure, an aerosol generating article is provided, wherein the aerosol generating article comprises: a substrate element comprising an aerosol generating substrate; and a tubular element comprising an integral first and second tubular portion, wherein the first tubular portion and the second tubular portion each constitute at least 10% of the length of the tubular element; wherein the first tubular portion has a first inner diameter and the second tubular portion has a second inner diameter, the second inner diameter being larger than the first inner diameter; wherein the first tubular portion comprises an inner tube segment and a first portion of an outer tube segment arranged around the inner tube segment, and the second tubular portion comprises a second portion of the outer tube segment extending beyond the end of the inner tube segment in the longitudinal direction of the tubular element, the first inner diameter being the inner diameter of the inner tube segment and the second inner diameter being the inner diameter of the second portion of the outer tube segment; The above inner tube segment and the above outer tube segment comprise a substantially continuous strip of web material wound in a plurality of spirals, an aerosol generating article.

[0162] The exemplary aerosol generating article immediately above may have any one of the features of any one of the aerosol generating articles described above, and such features are not repeated herein for the sake of brevity.

[0163] In other exemplary aerosol generating articles, the first and second tubular portions may each have different first and second outer diameters.

[0164] The substrate element may include a capsule containing an aerosol generating substrate. The capsule may be arranged upstream of the tubular element.

[0165] The first outer diameter may be smaller than the second outer diameter. The outer surface of the first tubular portion of the tubular element having the smaller first outer diameter may at least partially define an annular space within the aerosol generating article. Advantageously, the annular space may define a gutter or well for collecting excess aerosol generating material released from the capsule. The annular space may also collect aerosol generating material released from the capsule as the aerosol generating article moves around between consumer inhalations.

[0166] The first outer diameter may be at least 1 mm smaller than the second outer diameter. Optionally, the first outer diameter may be at least 2 mm smaller than the second outer diameter. More optionally, the first outer diameter may be at least 3 mm smaller than the second outer diameter.

[0167] The difference between the first and second outer diameters may be about 0.5 to about 3.5 mm, optionally about 1 mm to about 3 mm, and more optionally about 1.5 mm to about 2.5 mm. In a preferred example, the difference between the first and second outer diameters may be about 2 mm.

[0168] The ratio between the second outer diameter and the first outer diameter may be 1.2 to 1.8, preferably 1.3 to 1.6, and more preferably 1.3 to 1.5. In a preferred example, the ratio between the second outer diameter and the first outer diameter may be about 1.4.

[0169] The first tubular portion may include a first portion of an inner tube segment. The second tubular portion may include a second portion of an inner tube segment. The second tubular portion may include an outer tube segment arranged around the second portion of an inner tube segment. The first outer diameter may be the outer diameter of the first portion of the inner tube segment. The second outer diameter may be the outer diameter of the outer tube segment.

[0170] Advantageously, by forming tubular elements from inner and outer tube segments, it is possible to use different materials to form each of the inner and outer tube segments. In particular, different materials may be selected to form the inner and outer tube segments according to the specific physical requirements of each of the inner and outer tube segments.

[0171] The outer tube segment may overlap with the inner tube segment. The outer tube segment may overlap with at least 10% of the length of the inner tube segment, preferably at least 20% of the length of the inner tube segment, more preferably at least 30% of the length of the inner tube segment, and even more preferably at least 40% of the length of the inner tube segment. In a preferred example, the outer tube segment may overlap with about 50% of the length of the inner tube segment.

[0172] The inner tube segment may comprise a plurality of layers of web material. The inner tube segment may comprise 1 to 20 layers of web material. The inner tube segment may comprise a plurality of substantially continuous strips of web material. The substantially continuous strips may be wound spirally.

[0173] The outer tube segment may comprise a plurality of layers of web material. The outer tube segment may comprise 1 to 20 layers of web material. The outer tube segment may comprise a plurality of substantially continuous strips of web material. The substantially continuous strips may be wound spirally.

[0174] The inner tube segment and the outer tube segment may comprise a substantially continuous strip wound in a plurality of spirals of web material.

[0175] The web material may include one or more of paper, cardboard, acetate tow, or polylactic acid (PLA).

[0176] The width of the substantially continuous strip may be 10 mm to 50 mm. The thickness of the web material may be 0.05 mm to 0.1 mm.

[0177] Tubular elements can be hollow. Tubular elements can be hollow along their entire length.

[0178] A tubular element can define an internal cavity extending from the upstream end of the tubular element to the downstream end of the tubular element. The internal cavity can define an airflow path through the tubular element. The internal cavity can be substantially empty to allow for substantially unlimited airflow along the internal cavity.

[0179] The first tubular portion of the tubular element may have an outer diameter of at least about 4.0 mm, preferably at least about 4.5 mm, more preferably at least about 5.0 mm. Alternatively or additionally, the first tubular portion of the tubular element may have an outer diameter of less than about 7.0 mm, preferably less than about 6.5 mm or less than about 6.0 mm.

[0180] The first tubular portion of the tubular element may have an outer diameter of about 4.0 mm to about 7.0 mm, preferably about 4.0 mm to about 6.0 mm, and more preferably about 4.5 mm to 5.5 mm. In a preferred example, the first tubular portion of the tubular element may have an outer diameter of about 5.0 mm.

[0181] The periphery wall surface of the first tubular portion may have a thickness of at least about 0.5 mm, preferably at least about 1.0 mm, or at least about 2 mm. Alternatively or additionally, the periphery wall surface of the first tubular portion may have a thickness of less than about 3.0 mm, preferably less than about 2.5 mm or less than about 2 mm.

[0182] The peripheral wall surface of the first tubular portion may have a thickness of about 0.5 mm to 3.0 mm, preferably about 1.0 mm to 2.5 mm, and more preferably about 1.0 mm to 2.0 mm. In a preferred example, the peripheral wall surface of the first tubular portion may have a thickness of about 1.0 mm.

[0183] The first tubular portion of the tubular element may have a length of at least about 3 mm, preferably at least about 4 mm, more preferably at least about 5 mm. The first tubular portion of the tubular element may have a length of less than about 10 mm, preferably less than about 8 mm, more preferably less than about 7 mm.

[0184] The first tubular portion of the tubular element may have a length of about 3 mm to about 10 mm, preferably about 4 mm to 8 mm, more preferably about 5 mm to 7 mm. In a preferred example, the first tubular portion of the tubular element may have a length of about 6 mm.

[0185] The second tubular portion of the tubular element may have an outer diameter of at least about 5.0 mm, preferably at least about 6.0 mm, more preferably at least about 7.0 mm. Alternatively or additionally, the second tubular portion of the tubular element may have an outer diameter of less than about 10.0 mm, preferably less than about 9.0 mm, more preferably less than about 8.0 mm.

[0186] The second tubular portion of the tubular element may have an outer diameter of about 5.0 mm to about 10.0 mm, preferably about 6.0 mm to about 9.0 mm, and more preferably about 6.5 mm to 8.0 mm. In a preferred example, the second tubular portion of the tubular element may have an outer diameter of about 7.0 mm.

[0187] The peripheral wall surface of the second tubular portion may have a thickness of at least 0.5 mm, preferably at least about 1.0 mm, more preferably at least about 1.5 mm. Alternatively or additionally, the peripheral wall surface of the second tubular portion may have a thickness of less than about 3.5 mm, preferably less than about 3.0 mm, more preferably less than about 2.5 mm.

[0188] The peripheral wall surface of the second tubular portion may have a thickness of about 0.5 mm to 3.5 mm, preferably about 1.0 mm to 3.0 mm, and more preferably about 1.5 mm to 2.5 mm. In a preferred example, the peripheral wall surface of the second tubular portion may have a thickness of about 2.0 mm.

[0189] The second tubular portion of the tubular element may have a length of at least about 6 mm, preferably at least about 7 mm, more preferably at least about 8 mm. The second tubular portion of the tubular element may have a length of less than about 12 mm, preferably less than about 11 mm, more preferably less than about 10 mm.

[0190] The second tubular portion of the tubular element may have a length of about 6 mm to about 12 mm, preferably about 7 mm to 11 mm, more preferably about 8 mm to 10 mm. In a preferred example, the second tubular portion of the tubular element may have a length of about 9 mm.

[0191] The inner diameter of the tubular element may be smaller than the outer diameter of the capsule. Advantageously, this helps prevent the capsule from passing through the tubular element, that is, through the internal cavity within the tubular element.

[0192] The inner diameter of the tubular element may be at least 1 mm smaller than the outer diameter of the capsule. Optionally, the inner diameter of the tubular element may be at least 2 mm smaller than the outer diameter of the capsule. Additionally, optionally, the inner diameter of the tubular element may be at least 3 mm smaller than the outer diameter of the capsule.

[0193] The inner diameter of the tubular element may be uniform along the entire length of the tubular element. The tubular element may have an inner diameter of less than 4.5 mm, preferably less than 4.0 mm, and more preferably less than 3.5 mm.

[0194] The upstream end of the tubular element can be arranged to engage with the outer surface of the capsule. The tubular element can act as a retaining plug or element to restrict downstream movement of the capsule. Advantageously, by restricting the movement of the capsule, penetration of the capsule to remove its contents can be facilitated by providing a surface to pressurize.

[0195] The aerosol generating article may comprise a tubular body having a partially closed distal or upstream end and a partially closed downstream or downstream end. An upstream opening may be formed at the upstream end of the tubular body. The upstream opening may function as an air inlet. A downstream opening may be formed at the downstream end of the tubular body. The downstream opening may function as an air outlet. An airflow path may extend between the upstream opening and the downstream opening and pass through the internal cavity of the tubular body. A second tubular portion of the tubular element may be fixed to the inner surface of the tubular body.

[0196] The capsule may contain dry powder. The capsule may retain or contain at least about 5 mg of dry powder or at least about 10 mg of dry powder. The capsule may retain or contain about 900 mg or less of dry powder, about 30 mg or less of dry powder, or about 150 mg or less of dry powder. The capsule may retain or contain about 5 mg to about 300 mg of dry powder, about 10 mg to about 200 mg of dry powder, or about 25 mg to about 100 mg of dry powder.

[0197] The capsule contains pharmaceutically active particles, such as nicotine particles. As used herein, the term "nicotine" may refer to nicotine and nicotine derivatives such as free base nicotine, nicotine salts, etc.

[0198] The capsule may contain one or more nicotine salts.

[0199] Pharmaceutically active particles may have a mass center aerodynamic diameter of about 5 μm or less, or about 4 μm or less.

[0200] Pharmaceutically active particles may have a mass center aerodynamic diameter of at least about 0.5 μm, or at least about 1 μm.

[0201] Pharmaceutically active particles may have a mass center aerodynamic diameter of about 0.5 μm to about 4 μm.

[0202] The capsule may contain nicotine particles sufficient to provide at least 2 puffs, at least 5 puffs, or at least 10 puffs.

[0203] Each inhalation or "puff" can deliver about 0.1 mg to about 3 mg of nicotine particles to the user's lungs, about 0.2 mg to about 2 mg of nicotine particles to the user's lungs, or about 1 mg of nicotine particles to the user's lungs.

[0204] The capsule may retain or contain at least about 5 mg of nicotine particles or at least about 10 mg of nicotine particles.

[0205] The capsule may retain or contain about 900 mg or less of nicotine particles, about 300 mg or less of nicotine particles, or about 150 mg or less of nicotine particles.

[0206] The capsule may contain flavor particles.

[0207] According to another example of the present disclosure, a method for manufacturing a tubular element for an aerosol generating system is provided. The method may include the step of forming an inner tube. The inner tube may be formed by a plurality of layers of a first web material. The method may include the step of cutting the inner tube to form a plurality of inner tube segments. The method may include the step of supplying a plurality of inner tube segments along a transfer path. A predefined space may be provided between consecutive inner tube segments. The method may include the step of wrapping a plurality of inner tube segments with at least one layer of a second web material to form an outer tube around the inner tube segments. The method may include the step of cutting the outer tube in the space between the inner tube segments.

[0208] According to another example of the present disclosure, a method for manufacturing a tubular element for an aerosol generating system is provided. The method comprises: forming an inner tube from a plurality of layers of a first web material; cutting the inner tube to form a plurality of inner tube segments; feeding the plurality of inner tube segments along a transfer path, wherein there are predefined spaces between consecutive inner tube segments; wrapping the plurality of inner tube segments with at least one layer of a second web material to form an outer tube around the inner tube segments; and cutting the outer tube in the spaces between the inner tube segments.

[0209] Advantageously, a tubular element having first and second tubular parts having different inner diameters can be formed by wrapping a plurality of spaced inner tube segments within a web material to form an outer tube around the inner tube segments and cutting the outer tube in the space between the inner tube segments.

[0210] The step of forming an inner tube may include the step of spirally winding a plurality of substantially continuous strips of the first web material.

[0211] A plurality of inner tube segments can be wrapped with a plurality of layers of the second web material to form an outer tube around the inner tube segments. A plurality of inner tube segments can be wrapped parallel to the second web material.

[0212] According to another example of the present disclosure, a method for manufacturing a tubular element for an aerosol generating system is provided. The method may include the step of forming an inner tube from a plurality of layers of a first web material. The method may include the step of cutting the inner tube to form a plurality of inner tube segments. The method may include the step of forming an outer tube from a plurality of layers of a third web material. The outer tube may have an inner diameter substantially equal to the outer diameter of the inner tube. The method may include the step of cutting the outer tube to form a plurality of outer tube segments. The outer tube segments may have different lengths from the inner tube segments. The method may include the step of inserting the inner tube segment into the outer tube segment. The method may include the step of fixing the outer surface of the inner tube segment to the inner surface of the outer tube segment.

[0213] According to another example of the present disclosure, a method for manufacturing a tubular element for an aerosol generating system is provided. The method comprises: forming an inner tube from a plurality of layers of a first web material; cutting the inner tube to form a plurality of inner tube segments; and forming an outer tube from a plurality of layers of a third web material, wherein the outer tube has an inner diameter substantially equal to the outer diameter of the inner tube. A method comprising the steps of: cutting the outer tube to form a plurality of outer tube segments, wherein the outer tube segments have a different length from the inner tube segments; inserting the inner tube segments into the outer tube segments; and fixing the outer surface of the inner tube segments to the inner surface of the outer tube segments.

[0214] When referring to the inner diameter of an outer tube that is substantially identical to the outer diameter of an inner tube, the term "substantially identical" is intended to mean that at least one or possibly both of these diameters includes a suitable tolerance that allows the inner tube to be inserted into the outer tube without using excessive force, that is, a force that could damage one or the other of the inner and outer tube segments.

[0215] Advantageously, by forming inner and outer tube segments having different lengths and inserting the inner tube segment into the outer tube segment, a tubular element having first and second tubular parts having different inner or outer diameters can be formed.

[0216] The step of forming an inner tube may include the step of spirally winding a plurality of substantially continuous strips of the first web material.

[0217] The step of forming the outer tube may include the step of spirally winding a plurality of substantially continuous strips of the third web material.

[0218] The features described in relation to one of the above embodiments may be equally applied to other examples of the present disclosure.

[0219] The present invention is defined in the claims. However, a non-limiting, non-comprehensive list of embodiments is provided below. Any one or more features of these embodiments may be combined with any one or more features of other embodiments, embodiments, or aspects described herein.

[0220] Example Ex1: An aerosol generating article comprising: a material element including an aerosol generating material; and a tubular element including first and second tubular parts.

[0221] Example Ex2: An aerosol generating article in Example Ex1, wherein the tubular element comprises an integral first and second tubular portion.

[0222] Example Ex3: An aerosol generating article in Example Ex1 or Ex2, wherein the first tubular portion and the second tubular portion each constitute at least 10% of the length of the tubular element.

[0223] Example Ex4: An aerosol generating article in any one of Examples Ex1 to Ex3, wherein the first tubular portion has a first inner diameter and the second tubular portion has a second inner diameter, and the first inner diameter is different from the second inner diameter.

[0224] Example Ex5: An aerosol generating article in any one of Examples Ex1 to Ex3, wherein the first tubular portion has a first outer diameter and the second tubular portion has a second outer diameter, and the first outer diameter is different from the second outer diameter.

[0225] Example Ex6: An aerosol generating article in any one of Examples Ex2 to Ex5, wherein the first tubular portion and the second tubular portion each constitute at least 20% of the length of the tubular element.

[0226] Example Ex7: An aerosol generating article in Example Ex6, wherein the first tubular portion and the second tubular portion each constitute at least 30% of the length of the tubular element.

[0227] Example Ex8: An aerosol generating article in Example Ex7, wherein the first tubular portion and the second tubular portion each constitute at least 40% of the length of the tubular element.

[0228] Example Ex9: An aerosol generating article in any one of Examples Ex2 to Ex8, wherein the first tubular portion and the second tubular portion each constitute about 50% of the length of the tubular element.

[0229] Example Ex10: An aerosol generating article in any one of the previous examples, wherein the difference in inner diameter or outer diameter is formed by a step difference on the inner or outer surface of the tubular element.

[0230] Example Ex11: An aerosol generating article, wherein, in any one of the previous examples, the difference between the inner diameter or the outer diameter is at least 1 mm.

[0231] Example Ex12: An aerosol generating article in Example Ex11, wherein the difference between the inner diameter or outer diameter is at least 2 mm.

[0232] Example Ex13: An aerosol generating article in Example Ex12, wherein the difference between the inner diameter or outer diameter is at least 2.5 mm.

[0233] Example Ex14: An aerosol generating article in any one of the previous examples, wherein the first and second tubular portions each have different first and second inner diameters.

[0234] Example Ex15: An aerosol generating article in Example Ex14, wherein the second inner diameter is larger than the first inner diameter.

[0235] Example Ex16: An aerosol generating article in Example Ex15, wherein the ratio of the first inner diameter to the second inner diameter is 1.2 to 1.8.

[0236] Example Ex17: An aerosol generating article in Example Ex16, wherein the ratio of the first inner diameter to the second inner diameter is 1.3 to 1.7.

[0237] Example Ex18: An aerosol generating article in Example Ex17, wherein the ratio of the first inner diameter to the second inner diameter is 1.4 to 1.6.

[0238] Example Ex19: An aerosol generating article in Example Ex29, wherein the ratio of the first inner diameter to the second inner diameter is approximately 1.4.

[0239] Example Ex20: An aerosol generating article, wherein in any one of the prior examples, the first tubular portion comprises an inner tube segment and a first portion of an outer tube segment arranged around the inner tube segment, and the first inner diameter is the inner diameter of the inner tube segment.

[0240] Example Ex21: The aerosol generating article of Example Ex20, wherein the second tubular portion comprises a second portion of the outer tube segment that extends through the end of the inner tube segment in the longitudinal direction of the tubular element, and the second inner diameter is the inner diameter of the second portion of the outer tube segment.

[0241] Example Ex22: An aerosol generating article in Example Ex20 or Ex21, wherein the inner tube segment comprises a plurality of layers of a first web material.

[0242] Example Ex23: The aerosol generating article of Example Ex22, wherein the inner tube segment comprises 1 to 20 layers of the first web material.

[0243] Example Ex24: An aerosol generating article in Example Ex22 or Ex23, wherein the inner tube segment comprises a plurality of substantially continuous strips of the first web material.

[0244] Example Ex25: An aerosol generating article in Example Ex24, wherein the substantially continuous strip is wound spirally.

[0245] Example Ex26: An aerosol generating article in any one of Examples Ex22 to Ex25, wherein the first web material comprises one or more of paper, cardboard, acetate tow, or polylactic acid.

[0246] Example Ex27: An aerosol generating article in any one of Examples Ex22 to Ex26, wherein the thickness of the first web material is 0.05 mm to 0.1 mm.

[0247] Example Ex28: An aerosol generating article in any one of Examples Ex21 to Ex27, wherein the outer tube segment comprises one or more layers of the second web material.

[0248] Example Ex29: An aerosol generating article in Example Ex28, wherein the second web material is wrapped parallel to the inner tube segment.

[0249] Example Ex30: An aerosol generating article in Example Ex29, wherein the outer tube segment comprises a plurality of layers of the second web material wrapped parallel to around the inner tube segment.

[0250] Example Ex31: An aerosol generating article in Example Ex30, wherein the outer tube segment comprises 1 to 20 layers of the second web material.

[0251] Example Ex32: An aerosol generating article in any one of Examples Ex28 to Ex31, wherein the second web material comprises one or more of paper, cardboard, acetate tow, or polylactic acid.

[0252] Example Ex33: An aerosol generating article in any one of Examples Ex28 to Ex32, wherein the thickness of the second web material is 0.05 mm to 1.1 mm.

[0253] Example Ex34: An aerosol generating article, wherein, in any one of the prior examples, it further comprises a ventilation zone provided at a location along a second tubular portion.

[0254] Example Ex35: An aerosol generating article in Example Ex34, wherein the ventilation zone comprises a plurality of ventilation holes through the peripheral wall surface of the second tubular portion.

[0255] Example Ex36: The aerosol generating article of Example Ex34 or Ex35, wherein the aerosol generating article has a ventilation level of about 30%.

[0256] Example Ex37: An aerosol generating article in any one of the previous examples, wherein the described element is arranged upstream of the tubular element.

[0257] Example Ex38: In any one of the previous examples,

[0258] The above-described element is an aerosol-generating article in contact with the above-described tubular element.

[0259] Example Ex40: An aerosol generating article in any one of the previous examples, wherein the susceptor element comprises a susceptor.

[0260] Example Ex41: An aerosol generating article in any one of Examples Ex1 to Ex13, wherein the first and second tubular portions each have different first and second outer diameters.

[0261] Example Ex42: The aerosol generating article of Example Ex41, wherein the substrate element comprises a capsule containing an aerosol generating substrate.

[0262] Example Ex43: An aerosol generating article in Example Ex41 or Ex42, wherein the first outer diameter is smaller than the second outer diameter.

[0263] Example Ex44: An aerosol generating article in any one of Examples Ex41 to Ex43, wherein the ratio between the second outer diameter and the first outer diameter is 1.2 to 1.8.

[0264] Example Ex45: An aerosol generating article in Example Ex44, wherein the ratio between the second outer diameter and the first outer diameter is 1.3 to 1.6.

[0265] Example Ex46: An aerosol generating article in Example Ex45, wherein the ratio between the second outer diameter and the first outer diameter is 1.3 to 1.5.

[0266] Example Ex47: An aerosol generating article in Example Ex46, wherein the ratio between the second outer diameter and the first outer diameter is about 1.4.

[0267] Example Ex48: An aerosol generating article in any one of Examples Ex41 to Ex47, wherein the first tubular portion comprises a first portion of an inner tube segment, and the first outer diameter is the outer diameter of the first portion of the inner tube segment.

[0268] Example Ex49: The aerosol generating article of Example Ex46, wherein the second tubular portion comprises a second portion of the inner tube segment and an outer tube segment arranged around the second portion of the inner tube segment, wherein the second outer diameter is the outer diameter of the outer tube segment.

[0269] Example Ex50: An aerosol generating article in Example Ex48 or Ex49, wherein the inner tube segment comprises a substantially continuous strip of web material wound in a plurality of spirals.

[0270] Example Ex51: An aerosol generating article in any one of Examples Ex48 to Ex50, wherein the outer tube segment comprises a substantially continuous strip of web material wound in a plurality of spirals.

[0271] Example Ex52: An aerosol generating article in any one of Examples Ex41 to Ex51, wherein the inner diameter of the tubular element is smaller than the outer diameter of the capsule.

[0272] Example Ex53: A method for manufacturing a tubular element for an aerosol generating article, the method comprising: forming an inner tube from a plurality of layers of a first web material; cutting the inner tube to form a plurality of inner tube segments; supplying the plurality of inner tube segments along a transfer path, wherein there is a predefined space between consecutive inner tube segments; wrapping the plurality of inner tube segments with at least one layer of a second web material to form an outer tube around the inner tube segments; and cutting the outer tube in the space between the inner tube segments.

[0273] Example Ex54: The method of Example Ex53, wherein the step of forming an inner tube comprises the step of spirally winding a plurality of substantially continuous strips of the first web material.

[0274] Example Ex55: A method in Example Ex53 or Ex54, wherein the plurality of inner tube segments are wrapped with a plurality of layers of the second web material to form an outer tube around the inner tube segments.

[0275] Example Ex56: A method in any one of Examples Ex53 to Ex55, wherein the plurality of inner tube segments are wrapped in parallel with the second web material.

[0276] Example Ex57: A method for manufacturing a tubular element for an aerosol generating article, the method comprising: forming an inner tube from a plurality of layers of a first web material; cutting the inner tube to form a plurality of inner tube segments; forming an outer tube from a plurality of layers of a third web material, wherein the outer tube has an inner diameter substantially equal to the outer diameter of the inner tube; cutting the outer tube to form a plurality of outer tube segments, wherein the outer tube segments have a different length from the inner tube segments; inserting the inner tube segments into the outer tube segments; and fixing the outer surface of the inner tube segments to the inner surface of the outer tube segments.

[0277] Example Ex58: The method of Example Ex57, wherein the step of forming an inner tube comprises the step of spirally winding a plurality of substantially continuous strips of the first web material.

[0278] Example Ex59: In Example Ex57 or Ex58, the step of forming an outer tube comprises the step of spirally winding a plurality of substantially continuous strips of the third web material. Brief explanation of the drawing

[0279] Now, embodiments will be further described with reference to the drawings. Figure 1 is a schematic longitudinal cross-sectional view of an aerosol-generating article. FIG. 1a is a schematic longitudinal cross-sectional view of a tubular element of the aerosol generating article of FIG. 1, showing these features in more detail. FIG. 2 is a schematic longitudinal cross-sectional view of another aerosol-generating article. FIG. 2a is a schematic longitudinal cross-sectional view of a tubular element of the aerosol generating article of FIG. 2, showing these features in more detail. Figure 3 is a flowchart of a method for manufacturing a tubular element for an aerosol generating article. FIG. 4 is a schematic side view of an apparatus for forming a tube from a substantially continuous strip of web material wound spirally around a mandrel. FIG. 5 is a schematic side view of an apparatus for forming a tube from a plurality of substantially continuous strips of web material wound spirally around a mandrel. FIG. 6 is a schematic perspective view of another device for forming a tube by winding a plurality of substantially continuous strips of web material spirally. FIG. 7 is a schematic side view of an apparatus for wrapping inner tube segments parallel within a web material to form a substantially continuous outer tube and cutting the outer tube to a predetermined size. FIG. 7a is a schematic side view showing the spaced arrangement between the inner tube segments when supplied into the device of FIG. 7. FIGS. 8a to 8d are schematic cross-sectional views of the pre-forming, bonding, compression, and drying devices, respectively, used in the device of FIG. 7. FIG. 9 is a schematic side view showing the location where a substantially continuous outer tube containing an inner tube segment is cut by the cutter of the device of FIG. 7 to form individual tubular elements. FIG. 10a is a schematic diagram of a device for wrapping multiple layers of web material in parallel around an inner tube segment. FIG. 10b is a schematic side cross-sectional view of an outer tube subassembly produced by the device of FIG. 10a showing continuous cutting positions. FIG. 10c is a schematic side view showing an outer tube subassembly produced by the device of FIG. 10a after passing through the device of FIG. 10a 10 times. FIG. 10d is a schematic cross-sectional view of an inner tube segment wound spirally. FIG. 10e is a schematic cross-sectional view of an outer tube segment added to an inner tube segment of FIG. 10d after passing through the device of FIG. 10a 10 times. Figure 11 is a flowchart of another method for manufacturing tubular elements for aerosol generating articles. FIGS. 12a and FIGS. 12b are schematic longitudinal cross-sectional views of a tubular element inserted into an outer tube segment, respectively, in a disassembled and assembled state of the inner tube segment. FIG. 12c illustrates a rotary nozzle used to apply adhesive to the inner surface of the outer tube segment of the tubular element of FIG. 12a and FIG. 12b. FIG. 12d shows an enlarged view of the adhesive bond between the tubular elements and the inner and outer tube segments of FIG. 12a and FIG. 12b in an assembled state. FIG. 13 illustrates a device for assembling the tubular elements of FIG. 12a and FIG. 12b. FIG. 14 is a schematic longitudinal cross-sectional view of another tubular element in which an inner tube segment is inserted into an outer tube segment. Specific details for implementing the invention

[0280] Referring to FIG. 1, an aerosol generating article (1) comprising a plurality of elements assembled in the form of a rod is illustrated. The aerosol generating article (1) comprises a substrate element (2) containing an aerosol generating substrate and a downstream section (4) located downstream of the substrate element (2). Additionally, the aerosol generating article (1) comprises an upstream section (6) located upstream of the substrate element (2). The aerosol generating article (1) extends from an upstream or distal end (8) to a downstream or mouse end (10). The aerosol generating article has a total length of about 45 mm.

[0281] The downstream section (4) includes a tubular element (12) located immediately downstream of the base element (2), and the tubular element (12) is aligned longitudinally with the base element (2). In the example of FIG. 1, the upstream end of the tubular element (12) borders the downstream end of the base element (2). The tubular element (12) includes a first tubular part (14) and a second tubular part (16), the second tubular part (16) being downstream of the first tubular part (14). The first (14) and second (16) tubular parts are integral with the tubular element (12). That is, the first (14) and second (16) tubular parts each form a part of the tubular element (12) rather than separate components. Thus, the tubular element (12) including the first (14) and second (16) tubular parts is a single component of the aerosol generating article (1).

[0282] The first tubular portion (14) of the tubular element (12) defines an internal cavity (18) that extends completely from the upstream end (20) of the first tubular portion (14) to the downstream end (22) of the first hollow tubular portion (14). The internal cavity (18) is substantially empty, and thus a substantially unlimited airflow is activated along the internal cavity (18). Therefore, the first tubular portion (14) does not substantially contribute to the overall RTD of the aerosol generating article (1). More specifically, the RTD of the first tubular portion (14) is substantially 0 mm H2O. The first tubular portion (14) of the tubular element (12) is configured to act as a spacer or support element for the aerosol generating article (1).

[0283] The second tubular portion (16) of the tubular element (12) defines an internal cavity (24) that extends completely from the upstream end (22) of the second tubular portion (16) to the downstream end (26) of the second tubular portion (16). The internal cavity (24) is substantially empty, and thus a substantially unlimited airflow is activated along the internal cavity (24). The second tubular portion does not substantially contribute to the overall RTD of the aerosol generating article (10). More specifically, the RTD of the second tubular portion (16) is substantially 0 mm H2O. The second tubular portion (16) of the tubular element (12) is configured to act as an aerosol cooling element for the aerosol generating article (1).

[0284] The aerosol generating article (1) further comprises a ventilation zone (28) provided along the second tubular portion (16) of the tubular element (12). More specifically, the ventilation zone (28) is provided about 2 mm from the upstream end (22) of the second tubular portion (16). The ventilation zone (28) comprises a circumferential ring of perforations or ventilation holes extending through the wall surface of the second tubular portion (16). Air can be drawn in through the ventilation holes and through the second tubular portion (16) to achieve cooling of the stream of aerosol generated during heating of the substrate element (2). The ventilation level of the aerosol generating article (1) is about 25%.

[0285] In the example of FIG. 1, the downstream section (4) further includes a mouthpiece element (30) located downstream of the tubular element (12). More specifically, the mouthpiece element (30) is located immediately downstream of the second tubular portion (16) of the tubular element (12). The upstream end of the mouthpiece element (30) borders the downstream end (26) of the second tubular portion (16) of the tubular element (12). The mouthpiece element (30) is provided in the form of a cylindrical plug of low-density cellulose acetate. The mouthpiece element (30) further includes a wrapper or plug wrap (35) that surrounds the aerosol generating substrate. The mouthpiece element (30) has a length of about 12 mm and an outer diameter of about 7.1 mm.

[0286] The substrate element (2) comprises an aerosol generating substrate of one of the types described above. The substrate element (2) is in the form of a rod comprising the aerosol generating substrate. The aerosol generating substrate may substantially define the structure and dimensions of the rod (2). The rod (2) may further include a wrapper (not shown) surrounding the aerosol generating substrate. The substrate element (2) has an outer diameter of about 7.1 mm and a length of about 12 mm. However, it will be understood that these dimensions may change. For example, in other aerosol generating articles, the substrate element (2) may have a length of about 11 mm.

[0287] The aerosol generating article (1) further comprises an elongated susceptor element (32) within a substrate element (2). More specifically, the susceptor element (32) is arranged substantially longitudinally within the aerosol generating substrate, for example, so as to be approximately parallel to the longitudinal direction of the rod-shaped substrate element (2). The susceptor element (32) is located at a radial center position within the substrate element (2) and effectively extends along the longitudinal axis of the substrate element (2). The susceptor element (32) extends completely from the upstream end to the downstream end of the substrate element (2). In practice, the susceptor element (32) has substantially the same length as the substrate element (2). In the example of FIG. 1, the susceptor element (32) is provided in the form of a strip and has a length of about 12 mm, a thickness of about 60 μm, and a width of about 4 mm.

[0288] The upstream section (6) includes an upstream element (34) located immediately upstream of the base element (2), and the upstream element (34) is aligned longitudinally with the base element (2). In the example of FIG. 1, the downstream end of the upstream element (34) borders the upstream end of the base element (2). This advantageously prevents the susceptor element (44) from becoming detached. Additionally, this ensures that a consumer cannot accidentally come into contact with the heated susceptor element (34) after use. The upstream element (34) is provided in the form of a cylindrical plug of cellulose acetate surrounded by a rigid wrapper (not shown). The upstream element (34) has a length of about 5 mm.

[0289] The aerosol generating article (1) further comprises a wrapper (36) surrounding an upstream element (34), a base element (2), and a tubular element (12). The wrapper (36) extends from an upstream or distal end (8) of the aerosol generating article (1) to a downstream end (26) of the second tubular part (16). A ventilation hole in the ventilation zone (28) extends through the wrapper (36) and communicates with a ventilation hole within the tubular element (12). A mouthpiece element (30) is attached to the aerosol generating article (1) by a tipping paper (37) that surrounds a portion of the downstream end of the second tubular part (16) wrapped by the mouthpiece element (30) and the wrapper (36).

[0290] FIG. 1a illustrates the tubular element (12) of the aerosol generating article (1) of FIG. 1 in more detail. The first tubular part (14) has a length (L1) of about 8 mm, and the second tubular part (16) has a length (L2) of about 8 mm. Thus, the first tubular part (14) and the second tubular part (16) each constitute about 50% of the total length (L1 + L2) of the tubular element (12), which is about 16 mm. However, it will be understood that these lengths and their relative percentages may vary. For example, in other aerosol generating articles, the second tubular part may have a length of 9 mm.

[0291] The first tubular part (14) and the second tubular part (16) have the same outer diameter (D) of about 7.1 mm. ext It has a ) which is constant over the entire length (L1 + L2) of the tubular element (12). The first tubular part (14) and the second tubular part (16) have different inner diameters. The first tubular part (14) has a first inner diameter (D1) of about 3.3 mm. int ) has. Accordingly, the thickness of the surrounding wall surface of the first tubular part (14) is about 1.9 mm. The second tubular part (16) has a second inner diameter (D2) of about 5.0 mm. intIt has ). Therefore, the thickness of the surrounding wall of the second tubular part (16) is about 1.05 mm. The first inner diameter (D1) of the first tubular part (14) int ) is uniform over the length (L1) of the first tubular portion (14), and the second inner diameter (D2) of the second tubular portion (16) int ) is uniform over the length (L2) of the second tubular portion (16). The second inner diameter (D2) of the second tubular portion (16) int ) and the first inner diameter (D1) of the first tubular part (14) int The ratio between ) is approximately 1.52.

[0292] The tubular element (12) includes an inner tube segment (15) and an outer tube segment (17) surrounding the inner tube segment (15). The inner tube segment (15) has a length (L1) equal to the length of the first tubular part (14). The thickness of the periphery wall of the inner tube segment (15) is 0.85 mm. The outer tube segment (17) is longer than the inner tube segment (15) and extends past the downstream end (22) of the inner tube segment (15) by the length (L2) of the second tubular part. The outer tube segment (17) extends from the upstream end (20) of the tubular element (12) to the downstream end (26) of the tubular element (12). The thickness of the periphery wall of the outer tube segment (17) is 1.05 mm. Accordingly, the first tubular portion (14) of the tubular element (12) includes an inner tube segment (15) and a first portion of an outer tube segment (17) defined by a length (L1) arranged around the inner tube segment (15). The radial thickness of the first tubular portion (14) is equal to the combined thickness of the periphery walls of the inner (15) and outer (17) tube segments, which is 1.9 mm as previously described. The second tubular portion (16) includes a second portion of an outer tube segment (16) that extends beyond the downstream end (22) of the inner tube segment (15) in the longitudinal direction of the tubular element (12). The radial thickness of the second tubular portion (16) is equal to the thickness of the periphery walls of the outer tube segment (17). The first inner diameter (D1 int ) is the inner diameter of the inner tube segment (15), and the second inner diameter (D2 int ) is the inner diameter of the second part of the outer tube segment (17). The outer diameter of the inner tube segment (15) is the inner diameter of the outer tube segment (17), i.e., the second inner diameter (D2 int It is substantially the same as ).

[0293] The inner tube segment (15) of the tubular element (12) of FIG. 1a comprises a plurality of layers of the first web material. In particular, the inner tube segment (15) comprises a plurality of substantially continuous strips of the first web material wound spirally using a method further described below. The outer tube segment (17) of the tubular element (12) of FIG. 1a comprises one or more sheets of the second web material wrapped parallel to the inner tube segment (15) using a method further described below.

[0294] FIG. 2 is a schematic longitudinal cross-sectional view of another aerosol generating article (100). The aerosol generating article (100) is an inhaler article such as a dry powder inhaler. The aerosol generating article (100) comprises a tubular body (102) having a partially closed distal or upstream end (104) and a partially closed downstream or mouse end (106). An upstream opening (108) is formed at the upstream end (104) of the tubular body (102), and a downstream opening (110) is formed at the mouse end (106) of the tubular body (102). The upstream opening (108) acts as an air inlet, and the downstream opening (110) acts as an air outlet. The airflow path extends between the upstream opening (108) and the downstream opening (110) and passes through the internal cavity (107) of the tubular body (102). The upstream portion (109) of the internal cavity of the tubular body (102) near the upstream end (104) accommodates a capsule (111) containing nicotine particles.

[0295] The partially closed upstream end (104) of the tubular body (102) prevents the capsule (111) from falling out of the upstream end (104) of the tubular body (102). The diameter of the capsule (111) is larger than the diameter of the upstream opening (108) so that it cannot pass through the upstream opening (108). A tubular element (112) is provided downstream of the capsule (111). The tubular element (112) is fixed to the inner surface of the tubular body (102) and acts as a retaining plug to limit downstream movement of the capsule (111) and to keep the capsule (111) in the upstream area of ​​the tubular body (102).

[0296] The tubular element (112) includes a first tubular portion (114) and a second tubular portion (116), wherein the second tubular portion (116) is located downstream of the first tubular portion (114). The first (114) and second (116) tubular portions are integral with the tubular element (112). That is, the first (114) and second (116) tubular portions each form a part of the tubular element (112) rather than separate components. Therefore, the tubular element (112) including the first (114) and second (116) tubular portions is a single component of the aerosol generating article (100).

[0297] The first tubular portion (114) has a first outer diameter smaller than the inner diameter of the tubular body (102). The second tubular portion (116) has a second outer diameter substantially equal to the inner diameter of the tubular body (102). Thus, the first outer diameter of the first tubular portion (114) is different from the second outer diameter of the second tubular portion (116), and in particular, the first outer diameter is smaller than the second outer diameter. The tubular element is fixed to the inner surface of the tubular body (102) in the region of the second tubular portion (116).

[0298] The tubular element (112) defines an internal cavity (118) that extends completely from the upstream end of the tubular element (112) to the downstream end of the tubular element (112). The internal cavity (118) is substantially empty, and thus a substantially unlimited airflow is activated along the internal cavity (118). Since the inner diameter of the internal cavity (118) is smaller than the outer diameter of the capsule (111), the capsule is prevented from passing through the tubular element (112).

[0299] When in use, the consumer uses an external penetration tool (120) (shown as a dashed outline in FIG. 2) to penetrate the capsule (111) through the upstream opening (108). The penetration tool (120) is pushed into the capsule (111) through the upstream opening (108) to create a hole (122) inside the capsule (111), through which nicotine particles can exit the capsule (111). The actual downstream movement of the capsule (111) is restricted by a tubular element (112). The upstream end of the tubular element (112) makes border contact with the capsule (111) during penetration and keeps the capsule (111) in place, making penetration easier.

[0300] When a consumer inhales or sucks the mouse end (106) of the aerosol generating item (100), air is inhaled through the upstream opening (108) and through the upstream portion (109) of the internal cavity (107) of the tubular body (102) that accommodates the capsule (111). Nicotine particles exit the capsule and are entrained in the airflow through the tubular body (102). The airflow carrying nicotine particles passes through the internal cavity (118) of the tubular element (112) and enters the downstream portion (124) of the internal cavity (107) of the tubular body (102). The inner diameter of the downstream portion (124) of the internal cavity (107) of the tubular body (102) is larger than the inner diameter of the internal cavity (118) of the tubular element (112). As air passes from the tubular element (112) to the downstream portion (124) of the internal cavity (107) of the tubular body (102), expansion in the cross-section of the airflow path causes a vortex effect that helps mix nicotine particles with the airflow before they are inhaled into the consumer's mouth through the downstream opening (110).

[0301] The smaller first outer diameter of the first tubular portion (114) of the tubular element (112) defines an annular space (126) between the outer surface of the first tubular portion (114) and the inner surface of the tubular body (102). The annular space (126) defines a gutter or well that collects excess nicotine particles released from the capsule (111) but not entrained in the airflow when a consumer inhales the aerosol generating item (100). The annular space (126) also collects nicotine particles released from the capsule when the aerosol generating item (100) is moved between consumer inhalations. The annular space (126) created by the tubular element (112) acts as a barrier that reduces the possibility of nicotine particles leaking from the aerosol generating item (100) between consumer inhalations or between uses of the aerosol generating item (100).

[0302] FIG. 2a shows the tubular element (112) of the aerosol generating article (100) of FIG. 2 in more detail. The first tubular part (114) has a length (L1) of about 6 mm, and the second tubular part (116) has a length (L2) of about 9 mm. Thus, the first tubular part (114) and the second tubular part (116) each constitute about 50% of the total length (L1 + L2) of the tubular element (112). However, it will be understood that these lengths and their relative percentages may vary.

[0303] The first tubular part (114) and the second tubular part (116) have the same inner diameter (D) of about 3.0 mm. int It has a ) which is constant over the entire length (L1 + L2) of the tubular element (112). The first tubular part (114) and the second tubular part (116) have different outer diameters. The first tubular part (114) has a first outer diameter (D1) of about 5.0 mm. ext ) has. Accordingly, the thickness of the periphery wall of the first tubular part (114) is about 1.0 mm. The second tubular part (116) has a second outer diameter (D2) of about 7.0 mm. ext It has ). Therefore, the thickness of the peripheral wall surface of the second tubular part (16) is about 2.0 mm. The first outer diameter (D1) of the first tubular part (114) ext ) is uniform over the length (L1) of the first tubular portion (114), and the second outer diameter (D2) of the second tubular portion (116) ext ) is uniform over the length (L2) of the second tubular portion (116). The second outer diameter (D2) of the second tubular portion (116) ext ) and the first outer diameter (D1) of the first tubular part (114) ext The ratio between ) is about 1.4.

[0304] The tubular element (112) includes an inner tube segment (115) and an outer tube segment (117) that surrounds a portion of the inner tube segment (115). The inner tube segment (115) extends from an upstream end (119) of the tubular element (112) to a downstream end (121) of the tubular element (112). The inner tube segment (115) has a length (L1+L2) equal to the combined length of the first (114) and second (116) tubular parts. The outer tube segment (117) has a length (L2) and is therefore shorter than the inner tube segment (115). The outer tube segment (117) is positioned at the downstream end (121) of the tubular element (112). Thus, the upstream portion of the inner tube segment (115) defining the first tubular part (114) protrudes from the outer tube segment (117). Accordingly, the first tubular portion (114) of the tubular element (112) includes a first portion of an inner tube segment (115) defined by length (L1). The second tubular portion (116) includes a second portion of an inner tube segment defined by length (L2) and an outer tube segment (117) arranged around the second portion of the inner tube segment (115). The first outer diameter (D1 ext ) is the outer diameter of the first part of the inner tube segment (115) and the second outer diameter (D2 ext ) is the outer diameter of the outer tube segment (117). The outer diameter of the inner tube segment (115), i.e., the first outer diameter (D1 ext ) is substantially the same as the inner diameter of the outer tube segment (117).

[0305] The inner (115) and outer (117) tube segments of the tubular element (112) of FIG. 2a comprise a plurality of layers of web material. In particular, the inner (115) and outer (117) tube segments comprise a plurality of substantially continuous strips of web material wound spirally using a method further described below.

[0306] FIG. 3 illustrates a flowchart of a method for manufacturing a tubular element for an aerosol generating article, for example, the tubular element (12) of FIG. 1a. The method comprises a first step S1 of forming a substantially continuous inner tube from a plurality of layers of a first web material using a spiral winding process, which is further described below.

[0307] In the second step S2, the method comprises the step of cutting a substantially continuous inner tube to form a plurality of inner tube segments. The inner tube segments will extend to the full length of the first tubular portion of the tubular element. In the method of FIG. 3, the inner tube segments are cut as double-length inner tube segments, that is, the inner tube segments have twice the length of the first tubular portion. The double-length inner tube segments will undergo an additional cutting step to cut them to the final intended size. In another exemplary method, it will be understood that the inner tube segments may be cut as single-length inner tube segments, that is, the inner tube segments have the same length as the first tubular portion.

[0308] In the third step S3, the method comprises the step of supplying a plurality of inner tube segments along a transfer path, e.g., a conveyor belt or other means of transfer. The inner tube segments are supplied on a transfer path where their longitudinal axes are aligned. A predefined space is provided between consecutive inner tube segments. In the method of FIG. 3, the inner tube segments are double-spaced, that is, the predefined space between the inner tube segments is twice the length of the second tubular portion of the tubular element. It will be understood that in another exemplary method, the inner tube segments may be single-spaced, that is, the predefined space between the inner tube segments may be equal to the length of the second tubular portion of the tubular element.

[0309] In step S4, the method comprises wrapping a plurality of inner tube segments with at least one layer of a second web material to form an outer tube substantially continuous around the inner tube segments. The second web material is wrapped around the inner tube segments using a parallel wrapping method described further below.

[0310] In step S5, the method includes the step of cutting the outer tube in the space between the inner tube segments. If the method uses double-spaced double-length inner tube segments, the outer tube is cut at the midpoint of each space between the inner tube segments, and the inner tube segment wrapped by the outer tube is cut at the midpoint of each double-length inner tube segment to form individual tubular elements. If the method uses single-spaced single-length inner tube segments, the outer tube is cut in the space between the inner tube segments immediately following each inner tube segment to form individual tubular elements.

[0311] FIG. 4 illustrates a schematic side view of an apparatus (200) for forming a tube (240) from a substantially continuous strip (241) of web material wound spirally around a mandrel (245). FIG. 4 shows only a single strip of web material to illustrate the basic principle. However, it will be understood that this principle can be extended to multiple strips of web material to manufacture a thicker tube, as described later in relation to FIG. 5. It will also be understood that the strip (241) of web material is substantially continuous, that is, its length is much longer than that shown in FIG. 4. The strip (241) of web material will generally be stored on a reel or bobbin (not shown). The substantially continuous strip (241) of web material will be unwound from the reel and guided to the mandrel by one or more alignment and tension rollers (not shown).

[0312] A mandrel is an elongated straight bar or tube having a uniform outer diameter over its entire length, defining the inner diameter of the formed tube (240). A strip of web material (241) is fed to the mandrel at an angle α with respect to the longitudinal axis of the mandrel (245). The angle α of the strip of web material (241) as well as the formed spiral pitch are selected so that once the strip of web material (241) is wound, it follows a helical parallel trajectory without overlapping itself, so that the opposing side edges of the strip of web material are arranged adjacently or border each other when wound. A side cross-sectional view (246) of the top of the tube (240) is provided over the mandrel (245) of FIG. 4 to illustrate the parallel arrangement of the strip of web material (241) in a continuous rotation. The determination of the inflow angle α is described in more detail below in relation to FIG. 5.

[0313] FIG. 5 illustrates a schematic side view of an apparatus (300) for forming a tube (340) from a plurality of substantially continuous strips (341a to 341d) of web material wound spirally around a mandrel (345). The apparatus (300) of FIG. 5 is similar to the apparatus (200) of FIG. 4, but instead of using a single strip of web material as in FIG. 4, the apparatus (300) of FIG. 5 forms a tube (340) from a plurality of substantially continuous strips (341a to 341d) of web material. The apparatus (300) of FIG. 5 and the related method may be used to form an inner tube segment or an outer tube segment of a tubular element of an aerosol generating article.

[0314] Each of the multiple strips (341a to 341d) of the web material has the same width and is supplied to the mandrel (345) at an angle α with respect to the longitudinal axis of the mandrel (345). The angle α of each of the multiple strips (241) of the web material, as well as the pitch of the spiral formed by each strip, is selected so that each strip (241) of the web material does not overlap itself once wound but follows a helical parallel trajectory as shown in FIG. 4. The multiple strips (341a to 341d) of the web material are supplied to the bottom of the mandrel. The strip (341) of the web material is the top layer and forms the innermost layer of the tube (340). The strips (341b to 341d) of the web material are arranged continuously below the strip (341a) in a partially overlapping manner and form an additional partially overlapping layer of the tube (340). A side cross-sectional view (346) of the top of the tube (340) is provided on the mandrel (345) of FIG. 5 and shows a plurality of strips (341a to 341d) of web material forming a continuous overlapping layer of the tube (340). Strip (341a) forms the innermost layer and strip (341d) forms the outermost layer. The overlapping strips (341a to 341d) of web material help reinforce the tube (340) by the overlapping portion of the outer strips (341b to 341d) where the side edges of the strips (341a to 341d) reinforce the adjacent points of the tube (340).

[0315] It will be understood that the strips (341a to 341d) of the web material are substantially continuous, that is, their length is much longer than that shown in FIG. 5. Each strip (341a to 341d) of the web material will generally be stored on its own reel or bobbin (not shown). The substantially continuous strips (341a to 341d) of the web material will be unwound from the reel and guided to a mandrel by one or more respective alignment and tension rollers (not shown). FIG. 5 shows bending in the strips (341b to 341d), but this is for the sake of clarity of example. FIG. 5 shows only four strips (341a to 341d) of the web material, but it will be understood that any suitable number of strips can be used and the number of strips determines the specific thickness of the tube (340).

[0316] In the example of FIG. 5, the innermost strip (341a) of the web material does not have an adhesive coating, whereas the other strips (341b to 341d) of the web material have an adhesive coating (347) that substantially covers the entire inner surface herein. The outer surface of the strips (341b to 341d) is not coated with adhesive. It will be understood that other gluing or adhesive arrangements may be used. For example, the surface of the strips of the web material may be partially coated with adhesive. Additionally, the outer surface of the inner strips (341a to 341c) may instead be coated with adhesive.

[0317] Strips (341a to 341d) of the web material can be coated using a fast-acting glue, such as ethylene-vinyl acetate (EVA) glue. The advantage of the fast-acting glue is that the strip is fixed in a tubular shape during the spiral winding process. Slower-acting glues, such as polyvinyl acetate (PVA), can also be used alone or in combination with EVA. Since PVA reaches maximum strength once dried, it is desirable to have a dryer station downstream of the winding process. The glue is preferably a liquid glue applied via a glue roller or by a glue nozzle.

[0318] The inflow angle α of the strips (341a to 341d) of the web material depends on the strip width and thickness, the mandrel diameter, and the order of the specific strips within the plurality of strips (341a to 341d) supplied to the mandrel. The angle α used for the strips (341a to 341d) must be such that each strip can form a full circle and create an arrangement parallel to itself when wound around the mandrel, or around the mandrel and the lower strips, that is, the opposing side edges of each strip of the web material must be arranged adjacent to or border each other once wound, as shown in cross-section (346). That is, the pitch of the helical full rotation of the strip around the mandrel must be equal to the width of the strip.

[0319] The inflow angle α for the innermost strip wound on the mandrel can be calculated as follows:

[0320] Equation (1) :

[0321] Here, pitch is equal to the width of the strip, D is the inner diameter of the tube, and ðD is the inner surface of the tube, which is equal to the outer surface of the mandrel in this case.

[0322] Accordingly, by applying Equation 1 to a tube (340) with an inner diameter of 5 mm wound on a mandrel with an outer diameter of 5 mm, and to a strip of web material with a width of 10 mm, the inflow angle α for the innermost strip of FIG. 5, i.e., strip (341a), can be determined as follows:

[0323]

[0324] Therefore, angle α is equal to 32.5 degrees.

[0325] In the case of a continuous strip forming a continuous layer of tube, the winding diameter of the mandrel needs to take into account the lower layer that has already been wound. For example, when using standard 80 g / m2 (gsm) uncoated paper with a thickness of about 100 μm, for the second strip that manufactures the second layer, i.e., the strip (341b) of FIG. 5, the circumference for a mandrel with a diameter of 5 mm will be calculated for a diameter of 5.1 mm, i.e., the outer diameter of the mandrel plus the thickness of the first layer (341a).

[0326] In more general terms, the inflow angle α for a continuous strip wound on a mandrel can be calculated as follows:

[0327] Equation (2) :

[0329] Here, W and T are the width and thickness of the web material strip, respectively, D is the inner diameter of the tube or the outer diameter of the mandrel, N is the order of the web material strips within the plurality of strips, and N=1 represents the innermost strip.

[0330] Therefore, if Equation 2 is applied to a strip of web material with an inner diameter of 5 mm, a width of 10 mm, and a thickness of 100 μm, the fourth strip, i.e., the strip (341d) of FIG. 5, will have the same inflow angle α as follows.

[0331]

[0332] Therefore, the angle α for the fourth strip is equal to 31.0 degrees.

[0333] As the tube (340) is formed by winding strips (341a to 341d) of web material around one end of the mandrel (345), it is extended in length and advances toward the other end (not shown) of the mandrel (345) and is removed therefrom. A stable exit speed for the tube (340) is about 40 to 60 m / min. When using 10 mm wide strips (341a to 341d) of web material, this means that the tube (340) advances about 10 mm per turn or revolution of the mandrel (345). Thus, a suitable rotation speed for the mandrel (340) is 4000 revolutions per minute to 6000 revolutions per minute. The strips (341a to 341d) of web material advance toward the mandrel along the inner circumference of the tube per turn or revolution. Accordingly, in the case of a mandrel with a diameter of 5 mm, the strips (341a to 341d) are advancing toward the mandrel at a speed of 62 m / min to 94 m / min.

[0334] The thickness of the periphery wall of the tube depends not only on the thickness of the web material used but also on the number of strips of the web material. To create a periphery wall thickness of 1.05 mm for the outer tube segment (17) of the tubular element (12) of FIG. 1a using standard 80 g / m2 (gsm) uncoated paper with a thickness of about 100 μm, about 10 layers or strips of paper would be required. To create a periphery wall thickness of 0.85 mm for the inner tube segment (15) of the tubular element (12) of FIG. 1a using the same paper, about 8 or 9 layers or strips of paper would be required.

[0335] The inventors have discovered that it is possible to create a perimeter wall thickness of 1 mm using only three layers of a relatively thick web material, namely a web material having a thickness of about 0.33 mm. The inventors have also discovered that it is possible to create a thicker perimeter wall using more than 20 layers of a web material.

[0336] FIG. 6 illustrates a schematic perspective view of another device (400) for forming a tube by spirally winding a plurality of substantially continuous strips of web material. The device (400) of FIG. 6 is similar to and operates in the same manner as the device (300) of FIG. 5, but shows additional features used in the winding process. The device (400) includes a mandrel (445) on which a plurality of substantially continuous strips (448) of web material are wound. A drive unit (447) is provided at a first end of the mandrel (445) to rotate the mandrel (445) clockwise around the longitudinal axis of the mandrel (445) at a desired rotational speed. Since the tube (440) is formed by winding a strip (448) of web material spirally around a mandrel (445), the tube is also pulled along the mandrel (445) in the direction of arrow A by an elastic belt (451) wrapped around the outer surface of the tube (440) in the path of Fig. 8 and is driven infinitely by two vertical drums or rollers (450) on both sides of the tube (440).

[0337] The device (400) also includes smoothing rollers (not shown) positioned on both sides of the mandrel (445) to apply pressure to a layer of tube (440) formed from a strip (448) of web material and smooth any raised edges downward. The tube (400) may also enter a dryer or cooling station (not shown) to dry or cure the adhesive binding the strip (448) of web material. Finally, the device (400) includes a cutter (not shown) that cuts the substantially continuous tube (440) exiting the mandrel (445) into tube segments. The cutter may cut the tube (400) into double-length tube segments or single-length tube segments as needed.

[0338] FIG. 7 illustrates a schematic side view of an apparatus (500) for wrapping inner tube segments (503) in parallel on a web material (531) to form a substantially continuous outer tube (532) and to cut the outer tube (532) to a predetermined size. The inner tube segments (503) were produced by a spiral winding process, for example, by the apparatus (400) of FIG. 6, and are now passed to the apparatus (500) of FIG. 7 for further manufacturing.

[0339] In the device (500) of FIG. 7, a stream of inner tube segments (503) is supplied onto a conveyor (507) in the form of a conveyor. The longitudinal axes of the inner tube segments (503) are aligned when supplied onto the conveyor (507). The inner tube segments are double-length inner tube segments, and each inner tube segment has twice the length (L1) of the first tubular part (14) of the tubular element (12) of FIG. 1a, i.e., a length of 16 mm. There is a predefined space (505) between consecutive inner tube segments (503). The predefined space is equal to twice the length (L2) of the second tubular part (16) of the tubular element (12) of FIG. 1a, i.e., a length of 16 mm. A conveyor (507) transports a spaced inner tube segment (503) to a performing station or device (509), where the inner tube segment (503) is wrapped parallel to a substantially continuous band (531) of web material unwound from a reel or bobbin (511). The band (531) of web material is supplied to the performing device (509) such that its lateral sides are parallel to the longitudinal axis of the inner tube segment (503). A stream of spaced inner tube segments (503) is positioned on top of the band (531) of web material. In the performing device (509), the band (531) of web material is wrapped parallel to the longitudinal axis of the inner tube segment (503) such that the lateral sides of the band (531) of web material face each other, as described in more detail below with respect to FIG. 8a.

[0340] Once the inner tube segment (503) has been wrapped parallel to the band (531) of the web material, the wrapped inner tube segment (503) is passed by a conveyor (507) to an adhesive station or device (513) where glue or adhesive is applied to an area on one or both of the main surfaces of the band (531) of the web material near the lateral side of the band (531) of the web material. Then, as described in more detail below in relation to FIG. 8b, the lateral sides of the band (531) of the web material are bonded together by a border or overlapping interlock to form a substantially continuous outer tube (532) around the inner tube segment (503).

[0341] After bonding, as described in more detail below with reference to FIG. 8c, a substantially continuous outer tube (532) is passed by a conveyor (507) to a compression station or device (515) in which the lateral sides of the band (531) of the web material are compressed to provide a tight interlock between the lateral sides. Then, as described in more detail below with reference to FIG. 8d, the substantially continuous outer tube (532) is passed by a conveyor (507) to a drying or cooling station or device (517) to dry or cure the adhesive holding the lateral sides of the band of the web material together. Finally, the substantially continuous outer tube (532) including the inner tube segment (503) is passed by a conveyor (507) to a cutter (519) in which the outer tube (532) and the inner tube segments are cut to form individual tubular elements (512).

[0342] FIG. 7a is a schematic side view showing in more detail the spaced arrangement between inner tube segments (503) when supplied into the device (500) of FIG. 7. As previously described, the inner tube segments (503) are double-length inner tube segments each having a length (2L1) of 16 mm, that is, twice the length (L1) of the first tubular part (14) of the tubular element (12) of FIG. 1a. Each space (505) between consecutive inner tube segments (503) is a double space having a length (2L2) of 16 mm, that is, twice the length (L2) of the second tubular part (16) of the tubular element (12) of FIG. 1a. However, it will be understood that different double lengths or spaces may be used depending on the lengths of the first and second tubular parts of the tubular element. For example, the double space between inner tube segments may be 18 mm.

[0343] FIGS. 8a through 8d illustrate schematic cross-sectional views of the pre-forming (509), bonding (513), compression (515), and drying (517) devices, respectively, used in the device (500) of FIG. 7. Referring to FIG. 8a, the pre-forming device (509) comprises a flexible guide belt (521) that receives a band (531) of web material and a stream of an inner tube segment (503) on the upper surface of the guide belt (521). The guide belt (521) extends in a direction parallel to the longitudinal axis of the inner tube segment (503). The pre-forming device comprises a forming element (not shown) having a generally U-shaped or partially circular groove with a radius of curvature that gradually decreases along the length of the forming element. The guide belt (521) passes longitudinally along the groove within the forming element. The gradually decreasing radius of curvature of the groove causes the guide belt (521) and the band (531) of the web material received thereon to gradually fold or wrap around the inner tube segment (503), so that the lateral sides (531a and 531b) of the band (531) of the web material face each other.

[0344] Referring to FIG. 8b, the adhesive device (513) includes a glue head (523) that applies glue or adhesive to the lateral sides (531a and 531b) of the band (531) of the web material or to an area on one or both of the main surfaces of the band (531) of the web material near the lateral sides (531a and 531b) of the band (531) of the web material. Then, the lateral sides (531a and 531b) of the band (531) of the web material are bonded together by a border or overlapping interlock to form a substantially continuous outer tube (532) around the inner tube segment (503).

[0345] Referring to FIG. 8c, the compression device (515) includes a compressor (525) configured to press the lateral sides (531a and 531b) of the band of web material together to provide a tight interlock between the lateral sides (531a and 531b).

[0346] Referring to FIG. 8d, the drying or cooling device (517) includes a dryer for drying or curing the adhesive applied by the adhesive device to help provide a good bond.

[0347] FIG. 9 is a schematic side view showing the locations where a substantially continuous outer tube (532) containing inner tube segments (503) is cut by the cutter (519) of the device (500) of FIG. 7 to form individual tubular elements (512). In the substantially continuous outer tube (532), the inner tube segments (503) are double-length inner tube segments, each having a length (2L1) of 16 mm. Each space (505) between the substantially continuous inner tube segments (503) is a double space having a length (2L2) of 16 mm or 18 mm. The substantially continuous outer tube (532) is cut at locations (534 and 536) indicated by dashed lines in FIG. 9. At location (534), the substantially continuous outer tube (532) and the inner tube segments (503) are cut at the midpoint of each double-length inner tube segment (503). At position (536), the substantially continuous outer tube (532) is cut at the midpoint of each double space (505) between the inner tube segments (503). By cutting at the midpoint of each double length inner tube segment (503) and double space (505), individual tubular elements (512) are created having a first tubular part (14) with a length (L1) of 8 mm and a second tubular part (16) with a length (L2) of 8 mm or 9 mm, as shown in FIG. 1a.

[0348] FIGS. 10a through 10e illustrate an apparatus and method for wrapping an inner tube segment parallel to a web material and a resulting tubular element. When using a parallel wrapping process such as that used by the apparatus (500) of FIG. 7 to manufacture a tubular element as illustrated in FIG. 10e, it is desirable to create a peripheral wall thickness of about 0.5 to 1 mm for the outer tube segment so that the second tubular part of the tubular element has sufficient strength. There are two options for this. The first option involves using a single layer of appropriately thick web material. The standard web material used in the parallel wrapping process is 40 gsm paper with a thickness of about 55 μm. It is possible to use a thicker web material with a thickness of about 1 mm. However, when attempting to use a thicker web material, the bonding process becomes more complex, and the compression stage requires high pressure applied to the tube, which may compromise the ovality or roundness of the final tubular element. The second option is to use the parallel wrapping process multiple times, adding another layer of web material each time the parallel wrapping process is passed until the desired thickness is reached.

[0349] FIG. 10a illustrates a schematic diagram of an apparatus (600) for wrapping multiple layers of web material in parallel around an inner tube segment (603). In particular, the apparatus (600) of FIG. 10a is configured to wrap 10 layers of 40 gsm wrapping paper in parallel around an inner tube segment (603). This type of paper may have a thickness of 0.032 mm to 0.055 mm. For the purposes of this example, a thickness of 0.05 mm is used. The inner tube segment (603) is manufactured using the aforementioned spiral winding process and has an inner diameter of 3.3 mm and a peripheral wall thickness of 1.4 mm, providing an outer diameter of 6.1 mm. This inner tube segment (603) is illustrated in FIG. 10d. The final desired outer diameter of the outer tube is 7.1 mm. Therefore, a peripheral wall thickness of 0.5 mm is required. This can be produced by wrapping 10 layers of 40gsm paper in parallel around an inner tube segment (603).

[0350] The device (600) of FIG. 10a includes a parallel wrapping device (601) having a pre-forming (509), bonding (513), compression (515), and drying (517) device of FIG. 7. As in FIG. 7, a stream of spaced inner tube segments (603) is first fed into the parallel wrapping device (601), and a band (not shown) of web material is wrapped parallel around the spaced inner tube segments (603) to form a substantially continuous first outer tube (632).

[0351] The device further includes a rotary knife (661) that cuts the first outer tube (632) to form a plurality of first outer tube subassemblies (640). It should be noted that only one first outer tube subassembly (640) is illustrated in FIG. 10a. In the example of FIG. 10a, each first outer tube subassembly (640) includes a single-length inner tube segment (603a) at each end of the first outer tube subassembly (640), and the intermediate section (642) includes nine double-length inner tube segments (603b) arranged between the single-length inner tube segments (603a) at each end of the first outer tube subassembly (640). Thus, each first outer tube subassembly (640) includes 20 end-length tubular elements. The number of double-length inner tube segments (603b) in the middle section (642) of the first outer tube subassembly (640) can generally be denoted by N. In this example, N is equal to 9, and the device is configured to provide N+1 or 10 layers of web material.

[0352] Then, each of the plurality of first outer tube subassemblies (640) is fed back into a parallel wrapping device (601) as indicated by arrow B in FIG. 10a to wrap the plurality of first outer tube subassemblies (640) with a second layer (not shown) of web material to form a second outer tube (not shown) around the first outer tube subassemblies. The second outer tube of each first outer tube subassembly and one of the nine double-length inner tube segments are cut at the midpoint of the double-length inner tube segments to form a plurality of second outer tube subassemblies (not shown). Each second outer tube subassembly has a configuration similar to the first outer tube subassembly in that it includes a single-length inner tube segment at each end of the first outer tube subassembly and nine double-length inner tube segments between the single-length inner tube segments.

[0353] Then, a plurality of second outer tube subassemblies are fed back to a parallel wrapping device (601) and undergo additional wrapping and cutting steps to form additional outer tube subassemblies. Each time they pass through the parallel wrapping device (601), an additional layer of web material is added to the outer tube assembly. Thus, by feeding the outer tube subassemblies back through the parallel wrapping device an additional 8 (N-1) times, an outer tube having 10 (N+1) layers of web material can be produced. Each time the outer tube subassembly passes through the parallel wrapping device (601), the outer diameter of the forming element is adjusted to accommodate the additional layer of web material. Each time the outer tube subassembly passes through the parallel wrapping device (601) and is cut by a rotary knife (661), the outer tube subassembly is cut at the midpoint of the previously uncut inner tube segment.

[0354] FIG. 10b is a schematic side cross-sectional view of an outer tube subassembly (640) produced by the device of FIG. 10a, illustrating the locations of successive cut sections (indicated by dashed lines in FIG. 10b) having each of the outer tube subassemblies (640) pass through parallel wrapping devices (601). The first cut section is made at location (634a) to form the first outer tube subassembly. The second cut section is made at location (634b) to form the second outer tube subassembly. The third and fourth cut sections are made at locations (634c and 634d), respectively, to form the third and fourth outer tube subassemblies. Additional cut sections (not shown) are made until all nine double-length inner tube segments (603b) are cut. In this way, whenever the outer tube subassembly passes through the parallel wrapping device (601) and is cut, the outer tube subassembly is cut at the midpoint of the previously uncut inner tube segment (603b).

[0355] FIG. 10c is a schematic side view showing an outer tube subassembly (640) produced by the device of FIG. 10a after passing through the device (600) of FIG. 10a 10 times. The periphery wall thickness (T1) of the first tubular part of each tubular element is now 1.9 mm, that is, a thickness of 0.5 mm is added to the 1.4 mm thickness of the inner tube segment by adding 10 layers of 40 gsm paper. The periphery wall thickness (T2) of the second tubular part of each tubular element is now 0.5 mm and is defined by 10 layers of 40 gsm paper. The outer tube subassembly (640) comprises 20 end-length tubular elements (612), each having a length (Lp) of 16 mm, each comprising nine double-length inner tube segments (603b) in the middle portion (642) of the outer tube subassembly (640), which are each cut in half by the device (600) of FIG. 10a. The outer tube subassembly (640) is cut once at the cutting lines (634 and 635) at each end of each tubular element (612) to produce the end-length tubular elements (612). These tubular elements (612) are illustrated in FIG. 10e.

[0356] FIG. 11 is a flowchart of another method for manufacturing a tubular element for an aerosol generating article, for example, the tubular element (12) of FIG. 1a or the tubular element (112) of FIG. 2a. The method comprises a first step S1 of forming a substantially continuous inner tube from a plurality of layers of web material using the spiral winding process described above.

[0357] In the second step S2, the method comprises the step of cutting a substantially continuous inner tube to form a plurality of inner tube segments. In the case of the tubular element (12) of FIG. 1a, the inner tube segment (15) will be cut to the length (L1) of the first tubular part (14) of the tubular element (12). In the case of the tubular element (112) of FIG. 2a, the inner tube segment (115) will be cut to the length (L1+L2) of the tubular element (112). It will be understood that the inner tube may be cut to form double-length inner tube segments, in which case an additional cutting step will be required to cut the inner tube segment to the desired length.

[0358] In the third step S3, the method comprises the step of forming a substantially continuous outer tube from a plurality of layers of web material using the aforementioned spiral winding process. The web material used to form the outer tube may be of the same type as the web material used to form the inner tube, or, for example, a different web material may be used if different properties are required for the outer tube. The outer tube has an inner diameter substantially equal to the outer diameter of the inner tube.

[0359] In the fourth step S4, the method comprises the step of cutting a substantially continuous outer tube to form a plurality of outer tube segments. In the case of the tubular element (12) of FIG. 1a, the outer tube segment (17) will be cut to the length (L1+L2) of the tubular element (12). In the case of the tubular element (112) of FIG. 2a, the outer tube segment (117) will be cut to the length (L2) of the second tubular part (116) of the tubular element (112). It will be understood that the outer tube may be cut to form double-length outer tube segments, in which case an additional cutting step will be required to cut the outer tube segment to the desired length.

[0360] In step S5, the method comprises the step of inserting an inner tube segment into each of the outer tube segments. The outer tube segment has an inner diameter substantially equal to the outer diameter of the inner tube segment, but there is sufficient tolerance for easy insertion, that is, the insertion of the inner tube segment into the outer tube segment does not require excessive force. Preferably, the outer tube segment has an inner diameter slightly larger than the outer diameter of the inner tube segment, or the inner tube segment has an outer diameter slightly smaller than the inner diameter of the outer tube segment. A suitable tolerance is generally 0.1 mm to 0.3 mm.

[0361] In step S6, the method includes the step of fixing the outer surface of the inner tube segment to the inner surface of each outer tube segment. This may be performed by applying an adhesive to the outer surface of the inner tube segment or the inner surface of the outer tube segment, or both, prior to the insertion step S5. The step of fixing the inner and outer tube segments generally includes the step of curing or drying the adhesive to ensure a secure bond between the inner and outer tube segments and the tubular element having the integral first and second tubular parts.

[0362] FIGS. 12a through 12d illustrate how the steps of the method of FIG. 11 can be applied to manufacture a tubular element (712) having first and second tubular parts having different inner diameters. The tubular element (712) includes an inner tube segment (715) and an outer tube segment (717). The tubular element (712) has the same shape and size as the tubular element (12) of FIG. 1a. In particular, the dimensions of the inner tube segment (715) and the outer tube segment (717) of the tubular element (712) are the same as the inner tube segment (15) and the outer tube segment (17) of the tubular element (12) of FIG. 1a and are illustrated in FIG. 12a. Additionally, the arrangement of these components in the tubular element (712) is the same as the arrangement in the tubular element (12) of FIG. 1a. However, the outer tube segment (717) of the tubular element (712) of FIG. 12a is manufactured using a different method than that of the tubular element (12) of FIG. 1a. The outer tube segment (717) of the tubular element (712) of FIG. 12a is manufactured using a spiral winding process rather than wrapping one or layers of web material in parallel around the inner tube segment (715).

[0363] Referring to FIG. 12a, this indicates that the tubular element (712) is in a disassembled state, that is, the inner tube segment (715) is separated from the outer tube segment (717). Both the inner tube segment (715) and the outer tube segment (717) of the tubular element in FIG. 12a were manufactured using a spiral winding process, for example, using the device shown in FIG. 5 or FIG. 6. The inner tube segment (715) is configured to be inserted into the outer tube segment (717) in the direction of arrow C. The outer diameter of the inner tube segment (15) is 5 mm, which is substantially the same as the inner diameter of the outer tube segment (17) to achieve a tight fit. However, as discussed above in relation to FIG. 11, it will be understood that one or both of these diameters will have sufficient tolerance to allow the inner tube segment (15) to be inserted into the outer tube segment (17) without excessive force. Preferably, the inner tube segment (715) has an outer diameter smaller than the inner diameter of the outer tube segment (717). Any resulting gap (not shown) may be at least partially occupied by glue or adhesive to provide a fluid buffer during insertion, and once the adhesive hardens, may provide a hermetic joint between the inner (715) and outer (717) tube segments.

[0364] FIG. 12b illustrates the tubular element (12) of FIG. 12a in an assembled state in which an inner tube segment (15) is inserted into an outer tube segment (17). The arrangement of the inner tube segment (715) and the outer tube segment (717) within the tubular element (712) of FIG. 12a is the same as the arrangement of these components within the tubular element (12) of FIG. 1a.

[0365] FIG. 12c illustrates a rotary nozzle (772) used to apply a glue or adhesive line (773) circumferentially around the inner surface of the outer tube segment (717) of the tubular element (712) of FIG. 12a and FIG. 12b, which is shown in perspective. The glue line (773) is applied before the insertion of the inner tube segment (715). The glue is EVA glue, but other suitable glues may be used. The glue provides a connection between the inner (715) and outer (717) tube segments during and after the insertion of the inner tube segment (715). It will be understood that the glue line (773) may also be applied circumferentially to the outer surface of the inner tube segment (715).

[0366] FIG. 12d is a perspective view of the tubular element of FIG. 12a and FIG. 12b in an assembled state. To the right of FIG. 12d, there is an enlarged view E of the interface between the outer surface of the inner tube segment (715) and the outer tube segment (717) in the area enclosed by the circle labeled e in FIG. 12d. Enlarged view E shows an adhesive or glue line (773) between the inner (715) and outer (717) tube segments. The glue line (773) firmly attaches the inner (715) and outer (717) tube segments to provide a tubular element (712) having an integral first and second tubular part. The glue line (773) also helps to adjust the position of the inner (715) and outer (717) tube segments during insertion and creates a hermetic barrier that prevents leakage between the inner (715) and outer (717) tube segments.

[0367] FIG. 13 illustrates an apparatus (800) for assembling inner (715) and outer (717) tube segments of the tubular element (712) of FIG. 12a and FIG. 12b. The apparatus (800) includes a drum (874) rotatable about its longitudinal axis. The outer circumferential surface (874a) of the drum (874) holds a plurality of inner (715) and outer (717) tube segments, and the continuous inner (715) and outer (717) tube segments are arranged circumferentially around the drum and are parallel to each other. The longitudinal axis of each outer tube segment (717) is aligned with one longitudinal axis of each inner tube segment (715). Although not shown in FIG. 13, the inner tube segments (715) are arranged on a step that extends circumferentially around the drum and aligns the longitudinal axes of the inner (715) and outer (717) tube segments. The outer circumferential surface (874a) of the drum (874) is porous. The inner (715) and outer (717) tube segments are held on the outer circumferential surface (874a) of the drum (874) by air suction acting through the porous outer surface in a direction counteracting the centrifugal force acting on the inner (715) and outer (717) tube segments. However, the inner (715) and outer (717) tube segments can still slide longitudinally on the outer circumferential surface (874a) of the drum (874).

[0368] The device (800) further includes a fixed rail (875) that remains stationary for rotation of the drum (874). The fixed rail (875) has a camming surface (875a) on the side of the rail (875) facing the inner (715) and outer (717) tube segments. The camming surface (875a) tapers and widens in the direction of rotation of the drum (874). As the drum (874) rotates, the ends of the inner tube segment (715) facing the fixed rail (875) engage with the fixed rail (875) and are pushed into the outer tube segment (717) by the camming surface (875a) as the drum rotates.

[0369] The device (800) may be part of a larger overall manufacturing line for an aerosol generating article and may be placed between a spiral winding device, for example, the device of FIG. 5 or FIG. 6, and an additional device for assembling the aerosol generating article.

[0370] It will be understood that the steps of the method of FIG. 11 can also be applied to manufacture a tubular element having first and second tubular parts having different outer diameters. Such a tubular element (912) is illustrated in FIG. 14. The tubular element (912) includes an inner tube segment (915) and an outer tube segment (917). The tubular element (912) has the same shape and size as the tubular element (112) of FIG. 2a. In particular, the dimensions of the inner tube segment (915) and the outer tube segment (917) of the tubular element (712) are the same as the inner tube segment (115) and the outer tube segment (117) of the tubular element (112) of FIG. 2a. Although the front and back are reversed in FIG. 14, it will be understood that the arrangement of the inner tube segment (915) and the outer tube segment (917) within the tubular element (912) is the same as these components within the tubular element (112) of FIG. 2a. Both the inner tube segment (915) and the outer tube segment (917) within the tubular element (912) of FIG. 14 were manufactured using a spiral winding process, for example, using the device shown in FIG. 5 or FIG. 6.

[0371] For the purposes of this description and the appended claims, unless otherwise indicated, all numbers expressing amounts, quantities, percentages, etc., shall be understood in all cases to be modified by the term “about.” Additionally, all ranges include the disclosed maximum and minimum points and include any intermediate ranges that may or may not be specifically enumerated herein. Accordingly, in this context, the number A is understood as 5 percent (5%) of A ± A. In this context, the number A may be considered to include numerical values ​​within the general standard error for measuring the characteristic that the number A modifies. In some cases used in the appended claims, the number A may deviate by the percentages listed above, provided that the amount of deviation of A does not significantly affect the basic and novel feature(s) of the claimed invention. Additionally, all ranges include the disclosed maximum and minimum points and include any intermediate ranges that may or may not be specifically enumerated herein.

Claims

Claim 1 As an aerosol generating article, the article comprises: a substrate element including an aerosol generating material; and a tubular element including an integral first and second tubular portion, wherein the first tubular portion and the second tubular portion each constitute at least 10% of the length of the tubular element; wherein the first tubular portion has a first inner diameter and the second tubular portion has a second inner diameter; wherein the first inner diameter is different from the second inner diameter and the second inner diameter is larger than the first inner diameter; wherein the first tubular portion includes an inner tube segment and a first portion of an outer tube segment arranged around the inner tube segment, and the second tubular portion includes a second portion of the outer tube segment extending beyond the end of the inner tube segment in the longitudinal direction of the tubular element, wherein the first inner diameter is the inner diameter of the inner tube segment and the second inner diameter is the inner diameter of the second portion of the outer tube segment; An aerosol generating article, wherein the outer tube segment comprises one or more layers of a web material, and the web material is wrapped parallel to the inner tube segment. Claim 2 An aerosol generating article according to claim 1, wherein the difference in inner diameter is formed by a step within the inner surface of the tubular element. Claim 3 An aerosol generating article according to claim 1 or 2, wherein the difference in inner diameter is at least 1 mm. Claim 4 An aerosol generating article according to claim 1, wherein the ratio of the second inner diameter to the first inner diameter is 1.2 to 2.

5. Claim 5 An aerosol generating article according to claim 4, wherein the ratio of the second inner diameter to the first inner diameter is 1.4 to 1.

6. Claim 6 An aerosol generating article according to any one of claims 1 to 5, wherein the web material of the outer tube segment is a second web material and the inner tube segment comprises a plurality of layers of the first web material. Claim 7 In claim 6, the inner tube segment comprises a plurality of substantially continuous strips of the first web material, wherein the substantially continuous strips are wound spirally, an aerosol generating article. Claim 8 In claim 6 or 7, the first web material comprises an aerosol generating article comprising a cellulose material. Claim 9 An aerosol generating article according to any one of paragraphs 6 to 8, wherein the second web material comprises a cellulose material. Claim 10 In claim 8 or 9, the cellulose material comprises paper or cardboard, an aerosol-generating article. Claim 11 An aerosol generating article according to any one of claims 6 to 10, wherein the outer tube segment comprises a plurality of layers of the second web material wrapped parallel to the inner tube segment. Claim 12 An aerosol generating article comprising: a substrate element including an aerosol generating material; and a tubular element including an integral first and second tubular portion, wherein the first tubular portion and the second tubular portion each constitute at least 10% of the length of the tubular element; wherein the first tubular portion has a first inner diameter and the second tubular portion has a second inner diameter, the second inner diameter being larger than the first inner diameter; wherein the first tubular portion includes an inner tube segment and a first portion of an outer tube segment arranged around the inner tube segment, and the second tubular portion includes a second portion of the outer tube segment extending beyond the end of the inner tube segment in the longitudinal direction of the tubular element, the first inner diameter being the inner diameter of the inner tube segment and the second inner diameter being the inner diameter of the second portion of the outer tube segment; and wherein the inner tube segment and the outer tube segment comprise a substantially continuous strip of web material wound in a plurality of spirals. Claim 13 An aerosol generating article according to claim 12, wherein the ratio of the second inner diameter to the first inner diameter is 1.2 to 2.

5. Claim 14 In paragraph 12 or 13, the web material is an aerosol-generating article comprising a cellulose material. Claim 15 In paragraph 14, the above-mentioned cellulose material is an aerosol-generating article comprising paper or cardboard. Claim 16 An aerosol generating article according to any one of claims 1 to 15, further comprising a ventilation zone provided at a location following the second tubular portion. Claim 17 An aerosol generating article according to any one of claims 1 to 16, wherein the described element is arranged upstream of the tubular element and is in contact with the tubular element.

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