Aerosol generating article having tubular elements

Abstract

An aerosol generating article (10; 400) comprising a plurality of elements assembled in the form of a rod is provided. The plurality of elements includes a substrate element (6; 416) comprising an aerosol forming substrate (48) and a tubular element (18; 418). The tubular element (18; 418) is a single element comprising a first tubular portion (22), a second tubular portion (24), and a folded portion (26). The first tubular portion (22) defines a cavity (32) extending from a first end (28) of the first tubular portion (22) to a second end (34) of the first tubular portion (22). The second tubular portion (24) is located at least partially inside the cavity (32) defined by the first tubular portion (22), and the second tubular portion (24) forms an air inlet that is in fluid communication with the cavity (32). The folded portion (26) extends between the first end (28) of the first tubular portion (22) and the second tubular portion (24).

Description

Technology Field

[0001] The present invention relates to an aerosol generating article having a tubular element comprising a first tubular portion and a second tubular portion. Background Technology

[0002] Aerosol generating articles are known in the art in which an aerosol-forming 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 separated aerosol-forming substrate or material that 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-forming substrate by heat transfer from the heat source and are entrained in the air inhaled through the aerosol generating article. As the released compounds cool, they condense to form an aerosol.

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

[0004] A heated aerosol generating article is typically cigarette-shaped and comprises a plurality of elements or plugs. For example, such an article typically comprises a substrate plug comprising an aerosol-forming 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 to aid in aerosol formation. The second tubular plug generally borders the first tubular plug and has a different inner diameter compared to the first tubular plug. For example, the first tubular plug may have a smaller inner diameter to resist or prevent movement of the substrate plug within the article, for example, when an internal resistive heater blade is inserted into the substrate 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 can 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 into the user's lungs. Such 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 retain the capsule so that it can be easily penetrated, or otherwise help resist the movement of the capsule. 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 for both heated aerosol generators and non-heated aerosol generators, such as dry powder inhalers, can be difficult because airflow is restricted to 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 generator, it is important that the first and second tubular plugs are bordered and concentrically aligned.

[0008] It would be desirable to provide an aerosol-generating article that is easier to manufacture and reduces the need for precise placement and alignment of tubular plugs or elements.

[0009] According to the present disclosure, an aerosol generating article comprising a plurality of elements assembled in a rod shape is provided. The plurality of elements may include a substrate element comprising an aerosol-forming substrate and a tubular element. A hollow element may include a first tubular portion defining a cavity extending from a first end of a first tubular portion to a second end of a first tubular portion. The tubular element may include a second tubular portion located at least partially within the cavity defined by the first tubular portion, wherein the second tubular portion forms an air inlet in fluid communication with the cavity. The tubular element may include a folded portion extending between the first end of the first tubular portion and the second tubular portion.

[0010] According to an embodiment of the present disclosure, an aerosol generating article comprising a plurality of elements assembled in a rod shape is provided. The plurality of elements comprises a substrate element comprising an aerosol-forming substrate and a tubular element. The tubular element comprises a first tubular portion defining a cavity extending from a first end of the first tubular portion to a second end of the first tubular portion. The tubular element also comprises a second tubular portion located at least partially within the cavity defined by the first tubular portion, wherein the second tubular portion forms an air inlet in fluid communication with the cavity. The tubular element also comprises a folded portion extending between the first end of the first tubular portion and the second tubular portion.

[0011] The term "aerosol generating article" is used herein to refer to an article in which an aerosol generating substrate is heated to produce an inhalable aerosol and deliver it to a consumer. As used herein, the term "aerosol forming substrate" refers to a substrate in which an aerosol may be formed or generated. An aerosol forming substrate may generate an aerosol by releasing a volatile compound upon heating.

[0012] As used herein, the term “tubular element” refers to a generally 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 that defines at least one airflow conduit having a substantially cylindrical cross section and establishing an 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 geometric structures 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.

[0013] As used herein, the term “length” refers to the dimension of a component of an aerosol generating article in 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 position 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.

[0014] An aerosol generating article according to an embodiment of the present disclosure comprises a tubular element comprising a first tubular portion, a second tubular portion, and a folded portion. That is, the tubular element is a single element. The term “single element” is used herein to refer to a tubular element formed as a single piece or element. That is, the first tubular portion, the second tubular portion, and the folded portion are formed as a single piece or element. This is in contrast to an aerosol generating article described herein which may have separate tubular elements corresponding to the first tubular portion and the second tubular portion of the tubular element and must be assembled together during the manufacture of the aerosol generating article. The tubular element may be formed as a single element by being manufactured from a single piece of material, for example, a single sheet of web material.

[0015] By forming the tubular element as a single element, the tubular element is advantageously formed as a single piece. Advantageously, this eliminates any difficulty in positioning the first tubular part and the second tubular part relative to each other compared to forming the first tubular part and the second tubular part as separate elements. For example, since the single tubular element automatically achieves the advantages of this configuration, there is no need to interlock the first tubular part and the second tubular part. The single nature of the tubular element also ensures that the first tubular part and the second tubular part are axially aligned. Advantageously, this helps ensure smooth airflow through the tubular element and provide a consistent consumer experience.

[0016] The first end may be an upstream end of the first tubular portion, and the folded portion extends between the upstream end of the first tubular portion and the downstream end of the second tubular portion. Advantageously, providing a folded portion extending between the downstream end of the second tubular portion and the upstream end of the first tubular portion can facilitate the formation of a tubular element by applying only one or more folding steps to a tubular precursor, wherein the tubular precursor may be a simple tubular body.

[0017] The downstream end of the second tubular portion may be located within the cavity. Advantageously, this arrangement may result in a tubular element in which the first tubular portion has a larger inner diameter than the second tubular portion. This may be particularly advantageous in an embodiment in which the second tubular portion abuts a substrate element comprising an aerosol-forming substrate. For example, the smaller diameter of the second tubular portion may resist or prevent movement of the substrate element within the aerosol-generating article, for example, when an internally resistant heater blade is inserted into the substrate element.

[0018] In some embodiments, the folded portion extends between the upstream end of the first tubular portion and the downstream end of the second tubular portion, and the downstream end of the second tubular portion is located inside the cavity. Advantageously, in this arrangement, the folded portion may resist or prevent further movement of the second tubular portion into the cavity. Additionally, in this arrangement, the folded portion may define an annular recess extending between the upstream end of the first tubular portion and the downstream end of the second tubular portion. The annular recess may be particularly advantageous in an embodiment in which the substrate element comprises a capsule containing an aerosol-forming substrate and the aerosol-forming substrate comprises a powder, because the annular recess collects the powder and can reduce the likelihood of the powder leaking out of the aerosol-generating article once the capsule is penetrated.

[0019] The upstream end of the second tubular section may be located outside the cavity. The upstream end of the second tubular section may be in the same plane as the upstream end of the first tubular section. The second tubular section may be located entirely inside the cavity.

[0020] Preferably, the angle between the folded portion and the inner surface of the first tubular portion is less than 90 degrees. For example, the angle between the folded portion and the inner surface of the first tubular portion may be less than 85 degrees, less than 80 degrees, less than 75 degrees, less than 70 degrees, less than 65 degrees, less than 60 degrees, less than 55 degrees, less than 50 degrees, or less than 45 degrees.

[0021] Preferably, the angle between the folded portion and the outer surface of the second tubular portion is less than 90 degrees. For example, the angle between the folded portion and the outer surface of the second tubular portion may be less than 85 degrees, less than 80 degrees, less than 75 degrees, less than 70 degrees, less than 65 degrees, less than 60 degrees, less than 55 degrees, less than 50 degrees, or less than 45 degrees.

[0022] Preferably, the angle between the inner surface of the folded portion and the first tubular portion is equal to the angle between the outer surface of the folded portion and the second tubular portion. Advantageously, this arrangement can provide a folded portion having a substantially linear cross-sectional profile and coaxial alignment of the first tubular portion and the second tubular portion. Advantageously, this can facilitate the formation of tubular elements from a tubular body precursor using a simple folding step.

[0023] The first tubular portion may have a first inner diameter, and the second tubular portion may have a second inner diameter. The first inner diameter may be uniform or constant along the length of the first tubular portion. The second inner diameter may be uniform or constant along the length of the second tubular portion.

[0024] The second inner diameter may be smaller than the first inner diameter. The difference between the first inner diameter and the second inner diameter may be at least 1 mm, at least 2 mm, at least 3 mm, at least 4 mm, at least 5 mm, or at least 6 mm.

[0025] The first inner diameter may be at least 4 mm, at least 4.5 mm, at least 5 mm, at least 5.5 mm, at least 6 mm, at least 6.5 mm, at least 7 mm, at least 7.5 mm, at least 8 mm, or at least 8.5 mm. The first inner diameter may be less than 9 mm, less than 8.5 mm, less than 8 mm, less than 7.5 mm, less than 7 mm, less than 6.5 mm, less than 6 mm, less than 5.5 mm, less than 5 mm, or less than 4.5 mm. The first inner diameter may be 4 mm to 9 mm, 5 mm to 8.5 mm, 6 mm to 8.5 mm, 6.5 mm to 8 mm, or 6.5 mm to 7.5 mm.

[0026] The second inner diameter may be at least 1 mm, at least 1.25 mm, at least 1.5 mm, at least 1.75 mm, at least 2 mm, at least 2.25 mm, at least 2.5 mm, at least 2.75 mm, at least 3 mm, at least 3.25 mm, at least 3.5 mm, or at least 3.75 mm. The second inner diameter may be less than 4 mm, less than 3.75 mm, less than 3.5 mm, less than 3.25 mm, less than 3 mm, less than 2.75 mm, less than 2.5 mm, less than 2.25 mm, less than 2 mm, less than 1.75 mm, less than 1.5 mm, or less than 1.25 mm. The second inner diameter may be 1 mm to 4 mm, 2 mm to 3 mm, or 2.25 mm to 2.75 mm.

[0027] The first tubular part may have a first length, and the second tubular part may have a second length. The second length may be smaller than the first length.

[0028] Advantageously, providing a second tubular portion shorter than the first tubular portion can reduce the material required to form the tubular element. This may be particularly advantageous in an embodiment where the second tubular portion has a smaller inner diameter than the first tubular portion and is provided solely to resist or prevent movement of the substrate element within the aerosol generating article.

[0029] The second length may be less than 50% of the first length, less than 45% of the first length, less than 40% of the first length, less than 35% of the first length, less than 30% of the first length, less than 25% of the first length, less than 20% of the first length, less than 15% of the first length, or less than 10% of the first length.

[0030] The first length may be at least 10 mm, at least 13 mm, at least 15 mm, at least 20 mm, at least 25 mm, at least 30 mm, or at least 35 mm. The first length may be less than 40 mm, less than 35 mm, less than 30 mm, less than 25 mm, less than 20 mm, less than 15 mm, or less than 13 mm. The first length may be 10 mm to 40 mm, 10 mm to 30 mm, or 10 mm to 20 mm. The first length may be 13 mm to 30 mm, or 16 mm to 27 mm, or 18 mm to 23 mm.

[0031] The first tubular portion may have a first outer diameter, and the second tubular portion may have a second outer diameter. The first outer diameter may be uniform or constant along the length of the first tubular portion. The second outer diameter may be uniform or constant along the length of the second tubular portion.

[0032] The second outer diameter may be smaller than the first outer diameter. The difference between the first outer diameter and the second outer diameter may be at least 1 mm, at least 2 mm, at least 3 mm, at least 4 mm, at least 5 mm, or at least 6 mm.

[0033] The first outer diameter may be at least 4 mm, at least 4.5 mm, at least 5 mm, at least 5.5 mm, at least 6 mm, at least 6.5 mm, at least 7 mm, at least 7.5 mm, at least 8 mm, or at least 8.5 mm. The first outer diameter may be less than 9 mm, less than 8.5 mm, less than 8 mm, less than 7.5 mm, less than 7 mm, less than 6.5 mm, less than 6 mm, less than 5.5 mm, less than 5 mm, or less than 4.5 mm. The first outer diameter may be 4 mm to 9 mm, 5 mm to 8.5 mm, 6 mm to 8.5 mm, 6.5 mm to 8 mm, or 6.5 mm to 7.5 mm.

[0034] The second outer diameter may be at least 1 mm, at least 1.25 mm, at least 1.5 mm, at least 1.75 mm, at least 2 mm, at least 2.25 mm, at least 2.5 mm, at least 2.75 mm, at least 3 mm, at least 3.25 mm, at least 3.5 mm, or at least 3.75 mm. The second outer diameter may be less than 4 mm, less than 3.75 mm, less than 3.5 mm, less than 3.25 mm, less than 3 mm, less than 2.75 mm, less than 2.5 mm, less than 2.25 mm, less than 2 mm, less than 1.75 mm, less than 1.5 mm, or less than 1.25 mm. The second outer diameter may be 1 mm to 4 mm, 2 mm to 3 mm, or 2.25 mm to 2.75 mm.

[0035] In an embodiment where the downstream end of the second tubular portion is located inside the cavity, the longitudinal distance between the upstream end of the first tubular portion and the downstream end of the second tubular portion may be referred to as the overlap length. The overlap length may be at least 0.5 mm, at least 0.75 mm, at least 1 mm, at least 1.25 mm, at least 1.5 mm, at least 1.75 mm, at least 2 mm, at least 2.25 mm, at least 2.5 mm, or at least 2.75 mm. The overlap length may be less than 3 mm, less than 2.75 mm, less than 2.5 mm, less than 2.25 mm, less than 2 mm, less than 1.75 mm, less than 1.5 mm, less than 1.25 mm, less than 1 mm, or less than 0.75 mm. The overlap length may be 0.5 mm to 3 mm, 0.75 mm to 1.5 mm, or 0.9 mm to 1.1 mm.

[0036] The tubular element may have a length of at least 10 mm, at least 13 mm, at least 15 mm, at least 20 mm, at least 25 mm, at least 30 mm, or at least 35 mm. The length of the tubular element may be less than 40 mm, less than 35 mm, less than 30 mm, less than 25 mm, less than 20 mm, less than 15 mm, or less than 13 mm. The length of the tubular element may be 10 mm to 40 mm, 10 mm to 30 mm, or 10 mm to 20 mm. The length of the tubular element may be 13 mm to 30 mm, 16 mm to 27 mm, or 18 mm to 23 mm.

[0037] The tubular element may include at least one airflow aperture extending through a folded portion. Advantageously, the at least one airflow aperture may provide at least one additional path for air to flow into the cavity. In particular, airflow may enter the cavity through a second tubular portion and through at least one airflow aperture.

[0038] At least one airflow aperture may include a plurality of airflow apertures. The plurality of airflow apertures may include 2, 3, 4, 5, 6, 7, 8, 9, or 10 airflow apertures. Preferably, the airflow apertures are arranged symmetrically around a folded portion.

[0039] Tubular elements can be formed from any suitable material. Tubular elements can be formed from one or more of paper, cardboard, acetate tow, or polylactic acid (PLA). In a preferred embodiment, tubular elements are formed from at least one of paper and cardboard. Advantageously, forming tubular elements from at least one of paper and cardboard can provide one or more environmental and sustainable advantages compared to tubular segments formed from polymeric materials such as acetate.

[0040] Tubular elements are 100 g / m² 2 Up to 700 g / m² 2 , preferably 100 g / m² 2 Up to 400 g / m² 2 It can be formed from a material having a basis weight.

[0041] Preferably, the tubular element is located adjacent to the substrate element. Preferably, the tubular element is in contact with the substrate element. Preferably, the second tubular portion is in contact with the substrate element.

[0042] The base element may have a maximum outer diameter. Preferably, the maximum outer diameter of the base element is larger than the inner diameter of the second tubular portion. The difference between the maximum outer diameter of the base element and the second inner diameter may be at least 1 mm, at least 2 mm, at least 3 mm, at least 4 mm, at least 5 mm, or at least 6 mm.

[0043] Multiple elements may include mouthpiece elements. The mouthpiece element may be located at the downstream end of the aerosol generating article. A tubular element may be located between the base element and the mouthpiece element. Preferably, the mouthpiece element is located immediately downstream of the tubular element.

[0044] The upstream end of the substrate can define the upstream end of the aerosol-generating article. The upstream end of the tubular element can be adjacent to the downstream end of the substrate element. The upstream end of the mouthpiece element can be adjacent to the downstream end of the tubular element. The downstream end of the mouthpiece element can define the downstream end of the aerosol-generating article.

[0045] The mouthpiece element may comprise at least one mouthpiece filter segment of a fibrous filter material for filtering an aerosol generated from an aerosol-forming substrate. Suitable fibrous filter materials are known to those skilled in the art. Particularly preferably, at least one mouthpiece filter segment comprises a cellulose acetate filter segment formed of cellulose acetate tow.

[0046] Preferably, the mouthpiece element has low particulate filtration efficiency.

[0047] 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.

[0048] The mouthpiece element is preferably connected to one or more adjacent upstream components of the aerosol generating article by a tipping wrapper.

[0049] The mouthpiece element preferably has an outer diameter approximately equal to the outer diameter of the aerosol generating article. The mouthpiece element may have an outer diameter of about 5 mm to about 10 mm, or about 6 mm to about 8 mm. In a preferred embodiment, the mouthpiece element has an outer diameter of about 7.1 mm.

[0050] Preferably, the mouthpiece element 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, preferably, the mouthpiece element has a length of less than about 25 mm, preferably less than about 20 mm, and more preferably less than about 15 mm.

[0051] 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 embodiment, the mouthpiece element has a length of about 12 mm.

[0052] The aerosol generating article may include a ventilation zone at a location along a tubular element. Preferably, the ventilation zone is provided at a location along a first tubular portion.

[0053] Advantageously, the ventilation zone can provide desired cooling of the aerosol stream generated when the aerosol-forming substrate is heated and drawn in through the tubular element.

[0054] The ventilation zone may include a plurality of ventilation holes or perforations through the surrounding wall of the first tubular portion. Preferably, the ventilation zone includes at least one row of circumferential perforations. In some embodiments, the ventilation zone may include two rows of circumferential perforations. Preferably, each row of circumferential perforations includes 8 to 30 perforations.

[0055] Aerosol-generating products can have a ventilation level of at least about 5%.

[0056] The term "ventilation level" is used herein to denote the volume ratio of the airflow entering the aerosol-generating product through the ventilation zone (ventilation airflow) to the aerosol airflow and the ventilation airflow. The higher the ventilation level, the higher the dilution of the aerosol flow delivered to the consumer.

[0057] The aerosol-generating article may have a ventilation level of at least about 10%, preferably at least about 15%, more preferably about 20%. The aerosol-generating article has a ventilation level of less than about 60%, preferably less than about 45%, more preferably less than about 40%. In a particularly preferred embodiment, the aerosol-generating article has a ventilation level of about 30%.

[0058] Preferably, the substrate element is located immediately upstream of the tubular element. Preferably, the substrate element borders the upstream end of the tubular element.

[0059] Preferably, the substrate element is surrounded by a plug wrap.

[0060] The base element preferably has an outer diameter approximately equal to the outer diameter of the aerosol generating article. The mouthpiece element may have an outer diameter of about 5 mm to about 10 mm, or about 6 mm to about 8 mm. In a preferred embodiment, the base element has an outer diameter of about 7.1 mm.

[0061] Preferably, the mouthpiece element 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, preferably, the mouthpiece element has a length of less than about 25 mm, preferably less than about 20 mm, and more preferably less than about 15 mm.

[0062] 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 embodiment, the substrate element has a length of about 11 mm or about 12 mm.

[0063] The aerosol-forming substrate may be a solid aerosol-forming substrate. The aerosol-forming substrate may be a load of an aerosol-forming substrate.

[0064] The aerosol-forming substrate preferably includes an aerosol-forming agent.

[0065] 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 resistance to thermal degradation at temperatures 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.

[0066] 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.

[0067] The aerosol-forming 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-forming substrate.

[0068] The aerosol-forming 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-forming substrate.

[0069] The aerosol-forming 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-forming substrate.

[0070] The aerosol-forming 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-forming substrate.

[0071] The aerosol-forming 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-forming substrate.

[0072] The aerosol-forming material may include tobacco.

[0073] The aerosol-forming substrate may include a plurality of shredded pieces of tobacco material. The aerosol-forming substrate may include a plurality of shredded pieces of homogenized tobacco material.

[0074] As used herein in relation to the present invention, the term "shred" refers to an element having a length substantially greater than its width and thickness.

[0075] As used herein in relation to the present invention, the term "homogenized tobacco material" is used to describe a material formed by aggregating fine particulate tobacco material.

[0076] Pieces of homogenized tobacco material can be formed from 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.

[0077] The 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.

[0078] 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.

[0079] 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.

[0080] 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.

[0081] 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.

[0082] A piece of tobacco may have a width smaller than the inner diameter of the cavity defined by the first tubular part. A piece of tobacco may have a width substantially equal to the inner diameter of the cavity defined by the first tubular part. The ratio of the width of the piece of tobacco to the inner diameter of the cavity defined by the first tubular part may be at least 0.5, at least 0.55, at least 0.6, at least 0.65, at least 0.7, at least 0.75, at least 0.8, at least 0.85, at least 0.9, or at least 0.95.

[0083] Preferably, the tobacco piece has a width greater than the inner diameter of the second tubular portion. Advantageously, providing a second tubular portion smaller than the tobacco piece can facilitate the retention of the tobacco piece within the substrate element by the second tubular portion. The ratio of the inner diameter of the second tubular portion to the width of the tobacco piece may be less than 0.95, less than 0.9, less than 0.85, less than 0.8, less than 0.75, less than 0.7, less than 0.65, less than 0.6, less than 0.55, or less than 0.5.

[0084] The pieces of tobacco material can have a length of at least about 10 mm.

[0085] Pieces of tobacco material can have a length of about 40 mm or less.

[0086] The pieces of tobacco material can have a length of about 10 mm to about 40 mm.

[0087] Based on dry weight, at least about 20 weight percent of a plurality of pieces of tobacco material may extend along the entire length of the base element. Based on dry weight, at least about 20 weight percent of a plurality of pieces of tobacco material may have a length substantially equal to the length of the base element.

[0088] Up to about 60% by weight of a plurality of pieces of tobacco material based on dry weight may extend along the entire length of the base element. Up to about 60% by weight of a plurality of pieces of tobacco material based on dry weight may have a length substantially equal to the length of the base element.

[0089] 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 base element. 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 base element.

[0090] The size of the components of the aerosol-forming substrate, such as multiple pieces of tobacco material, can play a role in the heat distribution within the aerosol-forming substrate. Additionally, the size of the components of the aerosol-forming substrate can play a role in the RTD of the article.

[0091] The aerosol-forming substrate may include a plurality of pellets or granules of tobacco material. The aerosol-forming substrate may include a plurality of pellets or granules of homogenized tobacco material.

[0092] The aerosol-forming substrate may include one or more sheets of tobacco material.

[0093] The aerosol-forming substrate may include one or more sheets of homogenized tobacco material.

[0094] 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.

[0095] As used herein in relation to the present invention, individual thickness refers to the thickness of an individual sheet of tobacco material, whereas combined thickness refers to the total thickness of all sheets of tobacco material constituting the aerosol-forming substrate. For example, if the aerosol-forming 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 on the aerosol-forming substrate.

[0096] 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.

[0097] 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.

[0098] 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.

[0099] 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.

[0100] One or more sheets of tobacco material may each individually have a length substantially equal to the length of the aerosol-forming substrate.

[0101] One or more sheets of tobacco material may be one or more of curled, folded, pleated, and finely pleated sheets.

[0102] 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.

[0103] The substrate element may include a capsule, and the aerosol-forming substrate is contained within the capsule.

[0104] The capsule may include a first brittle portion at the upstream end of the capsule and a second brittle portion at the downstream end of the capsule. Advantageously, the first brittle portion and the second brittle portion may facilitate penetration of the capsule before use of the aerosol generating article.

[0105] The capsule may have an outer diameter smaller than the inner diameter of the cavity defined by the first tubular part. The capsule may have an outer diameter substantially equal to the inner diameter of the cavity defined by the first tubular part. The ratio of the outer diameter of the capsule to the inner diameter of the cavity defined by the first tubular part may be at least 0.5, at least 0.55, at least 0.6, at least 0.65, at least 0.7, at least 0.75, at least 0.8, at least 0.85, at least 0.9, or at least 0.95.

[0106] Preferably, the capsule has an outer diameter larger than the inner diameter of the second tubular portion. Advantageously, providing a second tubular portion smaller than the capsule can facilitate retention of the capsule at a desired location within the aerosol-generating article by the second tubular portion. The ratio of the inner diameter of the second tubular portion to the outer diameter of the capsule may be less than 0.95, less than 0.9, less than 0.85, less than 0.8, less than 0.75, less than 0.7, less than 0.65, less than 0.6, less than 0.55, or less than 0.5.

[0107] 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.

[0108] 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.

[0109] The capsule may contain one or more nicotine salts.

[0110] Pharmaceutically active particles may have a mass center aerodynamic diameter of about 5 μm or less, or about 4 μm or less.

[0111] Pharmaceutically active particles may have a mass center aerodynamic diameter of at least about 0.5 μm, or at least about 1 μm.

[0112] Pharmaceutically active particles may have a mass center aerodynamic diameter of about 0.5 μm to about 4 μm.

[0113] The capsule may contain nicotine particles sufficient to provide at least 2 puffs, or at least 5 puffs, or at least 10 puffs.

[0114] 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.

[0115] The capsule may retain or contain at least about 5 mg of nicotine particles or at least about 10 mg of nicotine particles.

[0116] 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.

[0117] The capsule may contain flavor particles.

[0118] The substrate element may also include a susceptor element. Preferably, the susceptor element is arranged within the aerosol-forming substrate.

[0119] The term "susceptor" is used herein to refer 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.

[0120] Preferably, the susceptor element is arranged in thermal contact with the aerosol-forming substrate. Thus, when the susceptor element is heated, the aerosol-forming substrate is heated by the susceptor element to generate an aerosol. The susceptor element may be arranged in direct physical contact with the aerosol-forming substrate.

[0121] The susceptor element can be a slender susceptor element.

[0122] In this document, the term "slender" is used to describe a component of an aerosol-generating article that has a length greater than its width and thickness.

[0123] The slender susceptor element may be arranged substantially longitudinally within the aerosol-forming substrate. That is, the longitudinal axis of the slender susceptor element may be approximately parallel to the longitudinal axis of the substrate element. For example, the longitudinal axis of the slender susceptor element may be within ±10 degrees of the longitudinal axis of the substrate element. The slender susceptor element may be located at a radially central position within the aerosol-forming substrate and may extend along the longitudinal axis of the substrate element.

[0124] The susceptor element can extend from the downstream end of the aerosol-forming substrate toward the upstream end of the aerosol-forming substrate.

[0125] The susceptor element can be extended from the upstream end of the aerosol-forming substrate toward the downstream end of the aerosol-forming substrate.

[0126] The susceptor element can extend from the upstream end of the aerosol-forming substrate to the downstream end of the aerosol-forming substrate. That is, the susceptor element can extend along the entire length of the aerosol-forming substrate.

[0127] The length of the susceptor element can be substantially the same as the length of the substrate element.

[0128] The susceptor element can be partially extended along the length of the substrate element.

[0129] The susceptor element can be spaced apart from the downstream end of the substrate element.

[0130] The susceptor element can be spaced apart from the upstream end of the substrate element.

[0131] The susceptor element can be spaced apart from both the downstream and upstream ends of the substrate element.

[0132] The length of the susceptor element may be smaller than the length of the substrate element.

[0133] The susceptor element can be completely surrounded within the aerosol-forming substrate. That is, the aerosol-forming substrate can completely surround the susceptor element.

[0134] The susceptor element can be in the form of a pin, rod, strip, or blade.

[0135] The susceptor element may have a length of at least about 5 mm, at least about 6 mm, or at least about 8 mm. The susceptor element may have a length of about 15 mm or less, about 12 mm or less, or about 10 mm or less.

[0136] 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.

[0137] The susceptor element 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.

[0138] The susceptor element 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.

[0139] The susceptor element can have a width of at least about 1 mm.

[0140] The susceptor element can have a width of about 5 mm or less.

[0141] The susceptor element may have a width of about 1 mm to about 5 mm.

[0142] The susceptor element may have a width smaller than the inner diameter of the cavity defined by the first tubular part. The susceptor element may have a width substantially equal to the inner diameter of the cavity defined by the first tubular part. The ratio of the width of the susceptor element to the inner diameter of the cavity defined by the first tubular part may be at least 0.5, at least 0.55, at least 0.6, at least 0.65, at least 0.7, at least 0.75, at least 0.8, at least 0.85, at least 0.9, or at least 0.95.

[0143] Preferably, the susceptor element has a width greater than the inner diameter of the second tubular portion. Advantageously, providing a second tubular portion smaller than the susceptor element can facilitate the retention of the susceptor element within the substrate element by the second tubular portion. The ratio of the inner diameter of the second tubular portion to the width of the susceptor element may be less than 0.95, less than 0.9, less than 0.85, less than 0.8, less than 0.75, less than 0.7, less than 0.65, less than 0.6, less than 0.55, or less than 0.5.

[0144] The susceptor element may have a thickness of at least about 0.01 mm, or at least about 0.5 mm.

[0145] The susceptor element may have a thickness of about 2 mm or less, about 500 μm or less, or about 100 μm or less.

[0146] The susceptor element 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.

[0147] The susceptor element may have a thickness of about 0.5 mm to about 2 mm.

[0148] The susceptor element can have a substantially circular cross-section.

[0149] The susceptor element can have a substantially constant cross-section along the length of the susceptor.

[0150] If the susceptor element has the form of a strip or 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 susceptor element in the form of a strip or blade may have a width of about 4 mm.

[0151] If the susceptor element 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 element in the form of a strip or blade may have a thickness of about 0.07 mm, or about 0.06 mm.

[0152] The susceptor element may be formed of any material capable of being induced heated to a temperature sufficient to generate an aerosol from the aerosol generating substrate. For example, the susceptor element may comprise metal or carbon.

[0153] The susceptor element may comprise or be made of a ferromagnetic material, for example, a ferromagnetic alloy, ferritic iron, ferromagnetic steel, or stainless steel. A suitable susceptor element 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.

[0154] Accordingly, parameters of the susceptor element, such as material type, length, width, and thickness, can all be changed to provide desired power dissipation within a known electromagnetic field. The susceptor element may be heated to a temperature exceeding 250°C during use.

[0155] A suitable susceptor element may include 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 element may have a protective outer layer, for example, a protective ceramic layer or a protective glass layer encapsulating the susceptor material. The susceptor element may include a protective coating formed by glass, ceramic, or an inert metal formed on the core of the susceptor material.

[0156] The susceptor element may be a multi-material susceptor element and may include a first susceptor material and a second susceptor material.

[0157] The aerosol generating article may include an upstream section located upstream of the first element. The upstream section may include one or more upstream elements. In some embodiments, 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 be in contact with 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 element.

[0158] 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 embodiment, the upstream element has an outer diameter of about 7.1 mm.

[0159] Preferably, the upstream element 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 has a length of preferably less than about 10 mm, preferably less than about 8 mm, and more preferably less than about 6 mm.

[0160] 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 embodiment, the upstream element may have a length of about 5 mm.

[0161] The aerosol generating article may additionally 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 additional 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. The wrapper may surround all components of the aerosol generating article. The wrapper may extend along the entire length of the aerosol generating article, i.e., from the upstream end of the aerosol generating article to the downstream end of the aerosol generating article.

[0162] The wrapper may be an outer wrapper. The wrapper may be an outermost wrapper. The outer surface of the wrapper may form at least a portion of the outer surface of the aerosol-generating article. The wrapper may be porous or equipped with a ventilation means.

[0163] Preferably, the wrapper is formed of paper. The wrapper has at least 20 g / m² 2 , at least 40 g / m² 2 , at least 60 g / m² 2 , at least 80 g / m² 2 , at least 100 g / m² 2, at least 120 g / m² 2 , at least 140 g / m² 2 , at least 160 g / m² 2 , or at least 180 g / m² 2 It can have a basis weight of 200 g / m². The wrapper is 200 g / m² 2 Less than 180 g / m² 2 Less than 160 g / m² 2 Less than 140 g / m² 2 Less than 120 g / m² 2 Less than 100 g / m² 2 Less than 80 g / m² 2 Less than 60 g / m² 2 Less than, or 40 g / m² 2 It can have a basis weight of less than 20 g / m². The wrapper is 20 g / m² 2 Up to 200 g / m² 2 , or 50 g / m² 2 Up to 100 g / m² 2 It can have a basis weight.

[0164] The present invention is defined in the claims. However, a non-limiting, non-comprehensive list of embodiments is provided below. Any one or more of the features of these embodiments may be combined with any one or more features of other embodiments, embodiments, or aspects described herein.

[0165] Example 1: An aerosol generating article comprising a plurality of elements assembled in the form of a rod, wherein the plurality of elements are,

[0166] A substrate element comprising an aerosol-forming substrate; and

[0167] Includes adjective elements, but the adjective elements are,

[0168] A first tubular portion defining a cavity extending from the first end of the first tubular portion to the second end of the first tubular portion;

[0169] A second tubular part formed at least partially located inside a cavity defined by a first tubular part and fluidly communicating with the cavity; and

[0170] An aerosol generating article comprising a folded portion extending between the first end of a first tubular portion and a second tubular portion.

[0171] Example 2: The aerosol generating article of Example 1, wherein the first end is the upstream end of the first tubular portion, and the folded portion extends between the upstream end of the first tubular portion and the downstream end of the second tubular portion.

[0172] Example 3: The aerosol generating article of Example 2, wherein the downstream end of the second tubular portion is located inside the cavity.

[0173] Example 4: An aerosol generating article in Example 2 or Example 3, wherein the upstream end of the second tubular portion is located outside the cavity.

[0174] Example 5: An aerosol generating article in any one of Examples 2 to 4, wherein the upstream end of the second tubular portion is in the same plane as the upstream end of the first tubular portion.

[0175] Example 6: An aerosol generating article in any one of the prior examples, wherein the second tubular portion is entirely located inside the cavity.

[0176] Example 7: In any one of the prior examples, the angle between the folded portion and the inner surface of the first tubular portion is less than 90 degrees, an aerosol generating article.

[0177] Example 8: An aerosol generating article, wherein in any one of the prior examples, the angle between the outer surface of the folded portion and the second tubular portion is less than 90 degrees.

[0178] Example 9: In any one of the prior examples, an aerosol generating article, wherein the first tubular portion has a first length and the second tubular portion has a second length, and the second length is smaller than the first length.

[0179] Example 10: The aerosol generating article of Example 9, wherein the second length is less than 50% of the first length, less than 40% of the first length, less than 30% of the first length, less than 20% of the first length, or less than 10% of the first length.

[0180] Example 11: An aerosol generating article, wherein, in any one of the prior examples, it further comprises at least one airflow aperture extending through a folded portion.

[0181] Example 12: The aerosol generating article of Example 11, wherein at least one airflow aperture comprises a plurality of airflow apertures.

[0182] Example 13: The aerosol generating article of Example 12, wherein the airflow aperture is symmetrically arranged around the folded portion.

[0183] Example 14: An aerosol generating article, wherein, in any one of the prior examples, the tubular element is formed from at least one of paper and cardboard.

[0184] Example 15: In any one of the prior examples, the tubular element is 100 g / m² 2 Up to 700 g / m² 2 , preferably 100 g / m² 2 Up to 400 g / m² 2 An aerosol generating article formed from a material having a basis weight of

[0185] Example 16: In any one of the prior examples, an aerosol generating article having a tubular element with a length of 10 mm to 30 mm, preferably 15 mm to 25 mm, preferably 15 mm to 20 mm.

[0186] Example 17: An aerosol generating article in any one of the prior examples, wherein the tubular element is located adjacent to the substrate element.

[0187] Example 18: An aerosol generating article in any one of the prior examples, wherein a plurality of elements further comprise a mouthpiece element.

[0188] Example 19: The aerosol generating article of Example 18, wherein the tubular element is positioned between the base element and the mouthpiece element.

[0189] Example 20: The aerosol generating article of Example 19, wherein the upstream end of the base element defines the upstream end of the aerosol generating article, the upstream end of the tubular element is adjacent to the downstream end of the base element, the upstream end of the mouthpiece element is adjacent to the downstream end of the tubular element, and the downstream end of the mouthpiece element defines the downstream end of the aerosol generating article.

[0190] Example 21: An aerosol generating article, wherein, in any one of the prior examples, a ventilation zone is additionally included at a location along a tubular element.

[0191] Example 22: An aerosol generating article, wherein in any one of the prior examples, the aerosol generating material is a rod of the aerosol generating material, and the material element further comprises a susceptor element arranged within the rod of the aerosol generating material.

[0192] Example 23: The aerosol generating article of Example 22, wherein the susceptor element is an elongated susceptor arranged longitudinally within an aerosol-forming substrate.

[0193] Example 24: Any one of Examples 1 to 21, wherein the substrate element further comprises a capsule, and the aerosol-forming substrate is an aerosol-generating article contained within the capsule.

[0194] Example 25: An aerosol generating article in Example 24, wherein the upstream end of the tubular element borders the downstream end of the capsule.

[0195] Example 26: The aerosol generating article of Example 24 or Example 25, wherein the capsule comprises a first brittle portion at the upstream end of the capsule and a second brittle portion at the downstream end of the capsule.

[0196] Now, embodiments will be further described with reference to the attached drawings. Brief explanation of the drawing

[0197] FIG. 1 illustrates a cross-sectional view of an aerosol-generating article according to a first embodiment of the present disclosure; FIG. 2 illustrates a cross-sectional view of a tubular element of the aerosol generating article of FIG. 1; FIG. 3 shows a perspective view of the tubular element of FIG. 2; FIGS. 4 through 13 illustrate exemplary methods and apparatus for forming tubular elements of FIGS. 2 and 3; FIG. 14 illustrates a cross-sectional view of an aerosol-generating article according to a second embodiment of the present disclosure; FIG. 15 illustrates a cross-sectional view of a tubular element of the aerosol generating article of FIG. 14; FIG. 16 shows a perspective view of the tubular element of FIG. 15. Specific details for implementing the invention

[0198] FIG. 1 illustrates a cross-sectional view of an aerosol generating article (10) according to a first embodiment of the present disclosure. The aerosol generating article (10) comprises a plurality of elements assembled in a rod shape and aligned axially along the longitudinal direction (12) of the aerosol generating article (10).

[0199] A plurality of elements include an upstream element (14), a base element (16), a tubular element (18), and a mouthpiece element (20). The aerosol generating article (10) extends from an upstream end (15) to a downstream end (17). The aerosol generating article (10) has a total length of about 60 mm to about 80 mm.

[0200] The tubular element (18) is located immediately downstream of the base element (16), and the tubular element (18) is aligned longitudinally with the base element (16). In the embodiment of FIG. 1, the upstream end of the tubular element (18) borders the downstream end of the base element (16). FIG. 2 and FIG. 3 illustrate the tubular element (18) in more detail.

[0201] The tubular element (18) comprises a first tubular part (22) and a second tubular part (24) connected to the first tubular part (22) by a folded part (26) having an annular shape. The folded part (26) extends between the upstream end (28) of the first tubular part (22) and the downstream end (30) of the second tubular part (24). The folded part (26) has a linear cross-sectional shape that forms an angle of less than 90 degrees with respect to the inner surface of the first tubular part (22) and the outer surface of the second tubular part (24). As a result of this arrangement, the downstream end (30) of the second tubular part (24) is located inside the first tubular part (22). The tubular element (18) is formed as a single element, so that the first tubular part (22), the second tubular part (24), and the folded part (26) are formed as a single piece from a continuous material.

[0202] The first tubular section (22) defines a cavity (32) that extends completely from the upstream end (28) of the first tubular section (22) to the downstream end (34) of the first tubular section (22). The cavity (32) is substantially empty, and thus airflow through the cavity (32) can flow substantially without restriction. Therefore, the first tubular element (22) does not substantially contribute to the total resistance-to-draw (RTD) of the aerosol generating article (10). That is, the RTD of the first tubular section (22) is substantially 0 mm of water. The first tubular section (22) functions as an aerosol cooling element for the aerosol generating article (10).

[0203] The second tubular section (24) defines an airflow passage (36) that extends completely from the upstream end (38) of the second tubular section (24) to the downstream end (30) of the second tubular section (24). The airflow passage (36) is substantially empty, and thus airflow through the airflow passage (36) can flow substantially without restriction. Therefore, the second tubular section (24) does not substantially contribute to the overall RTD of the aerosol generating article (10). That is, the RTD of the second tubular section (24) is substantially 0 mm of water. The second tubular section (24) functions as a support element that prevents the movement of the base element (16) toward the downstream end (17) of the aerosol generating article (10). To support this function, the inner diameter (40) of the second tubular part (24) is smaller than the inner diameter (42) of the first tubular part (22) and smaller than the outer diameter of the base element (16). In a specific embodiment illustrated in FIGS. 1 to 3, the inner diameter of the first tubular part (22) is about 6.5 mm to about 7.5 mm, and the inner diameter of the second tubular part (24) is about 2.25 mm to about 2.75 mm.

[0204] The tubular element (18) has a length of about 10 mm to about 20 mm. The first tubular part (22) has a similar length, and the total length of the tubular element (18) can be defined when the second tubular part (24) is located entirely within the cavity (32) defined by the first tubular part (22). The second tubular part (24) has a length of less than 50% of the length of the first tubular part (22).

[0205] The aerosol generating article (10) further comprises a ventilation zone (44) provided along the first tubular portion (22) of the tubular element (18). The ventilation zone (44) comprises a circumferential ring of ventilation holes extending through the wall of the first tubular portion (22). Air can be drawn in through the ventilation holes and through the first tubular portion (22) to achieve cooling of the aerosol stream generated during heating of the substrate element (16). The ventilation level of the aerosol generating article (10) is approximately 25%.

[0206] The mouthpiece element (20) is located immediately downstream of the first tubular portion (22) of the tubular element (18). The upstream end of the mouthpiece element (20) borders the downstream end (34) of the first tubular portion (22) of the tubular element (18). The mouthpiece element (20) is provided in the form of a cylindrical plug of low-density cellulose acetate. The mouthpiece element (20) has a length of about 12 mm and an outer diameter of about 7.1 mm. A mouthpiece plug wrap (46) is wrapped around the mouthpiece element (20).

[0207] The substrate element (16) comprises an aerosol-forming substrate (48) of one of the aforementioned types. The substrate element (16) is in the form of a rod comprising the aerosol-forming substrate (48). The aerosol-forming substrate (48) can substantially define the structure and dimensions of the substrate element (16). A substrate plug wrap (50) is wrapped around the substrate element (16). The substrate element (16) has an outer diameter of about 7.1 mm and a length of about 12 mm.

[0208] The aerosol generating article (10) also includes an elongated susceptor element (52) within a substrate element (16). The susceptor element (52) is arranged substantially longitudinally within the aerosol generating substrate (48) and extends substantially parallel to the longitudinal direction (12). The susceptor element (52) is located at a radial center position within the substrate element (16) and effectively extends along the longitudinal axis of the substrate element (16). The susceptor element (52) extends completely from the upstream end to the downstream end of the substrate element (16). In practice, the susceptor element (52) has substantially the same length as the substrate element (16). In the embodiment of FIG. 1, the susceptor element (52) 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. The inner diameter (40) of the second tubular part (24) is smaller than the width of the susceptor element (52) so that the susceptor element (52) is contained within the base element (16).

[0209] The upstream element (14) is located immediately upstream of the base element (16), and the upstream element (14) is aligned longitudinally with the base element (16). In the embodiment of FIG. 1, the downstream end of the upstream element (14) borders the upstream end of the base element (16). This advantageously prevents the susceptor element (52) from becoming detached and ensures that the consumer cannot accidentally come into contact with the heated susceptor element (52) after use. The upstream element (14) is provided in the form of a cylindrical plug of cellulose acetate surrounded by an upstream plug wrap (54). The upstream element (14) has a length of about 5 mm.

[0210] The aerosol generating article (10) also includes an outer wrapper (56) surrounding an upstream element (14), a base element (16), and a tubular element (18), and a tipping wrapper (58) surrounding a portion of a mouthpiece element (20) and a tubular element (18).

[0211] FIGS. 4 through 13 illustrate an exemplary method and apparatus for forming a tubular element (18). The method begins with a tubular precursor or tubular body (100) comprising a simple cardboard tube. In the first step illustrated by the three diagrams of FIG. 4, a first folding force is applied to a first end (102) of the tubular body (100) by a flanging mandrel (104) to form a flanged tube (106) comprising a first tubular portion (22) and an annular flanged portion (108). The first tubular portion (22) defines a cavity (32) extending from the upstream or first end (28) of the first tubular portion (22) to the downstream or second end (34) of the first tubular portion (22). The flanged portion (108) extends from the first end (28) of the first tubular portion (22) toward the longitudinal axis of the tubular body (100). To facilitate folding of the tubular body (100) to form a flanged tube (106), the flanged mandrel (106) is rotated about its longitudinal axis while applying a first folding force to the first end (102) of the tubular body (100).

[0212] FIGS. 5 through 8 illustrate exemplary first or internal mandrel (200) and second or external mandrel (300) that can be used to convert a flanged tube (106) into a tubular element (18).

[0213] An internal mandrel (200) is illustrated in FIG. 5 and FIG. 6, which respectively illustrate a perspective view and a cross-sectional view of the internal mandrel (200). The internal mandrel (200) generally has a cylindrical shape and includes a first cylindrical portion (202) defining a first cylindrical outer surface (204) and a second cylindrical portion (206) defining a second cylindrical outer surface (208). The internal mandrel (200) also defines a concave chamfered outer surface (210) extending between the first cylindrical outer surface (204) and the second cylindrical outer surface (208). The first cylindrical outer surface (204), the second cylindrical outer surface (208), and the concave chamfered outer surface (210) together form an internal mandrel forming surface.

[0214] The outer mandrel (300) is illustrated in FIGS. 7 and FIGS. 8, which illustrate a perspective view and a cross-sectional view of the outer mandrel (300), respectively. The outer mandrel (300) generally has a tubular shape and includes a recess (302) defining a first cylindrical inner surface (304) and a second cylindrical inner surface (308). The outer mandrel (300) also defines a truncated conical inner surface (310) extending between the first cylindrical inner surface (304) and the second cylindrical inner surface (308). The first cylindrical inner surface (304), the second cylindrical inner surface (308), and the truncated conical inner surface (310) together form an outer mandrel forming surface. The recess (302) is shaped such that the outer mandrel forming surface is complementary to the shape of the inner mandrel forming surface.

[0215] FIGS. 9 through 13 illustrate an exemplary method of using an inner mandrel (200) and an outer mandrel (300) to convert a flanged tube (106) into a tubular element (18). In the first step illustrated in FIG. 9, the flanged portion (108) of the flanged tube (106) is inserted into the recess (302) of the outer mandrel (300), and the inner mandrel (200) is inserted into the cavity (32) defined by the first tubular portion (22). In the second step illustrated in FIG. 10, the inner mandrel (200) and the outer mandrel (300) advance toward each other until the edges of the second cylindrical portion (206) and the truncated conical surface (310) engage with the flanged portion (108) of the flanged tube (106). In the third step illustrated in FIG. 11, the inner mandrel (200) and the outer mandrel (300) advance further toward each other to apply a second folding force to the flanged portion (108) of the flanged tube (106). The second folding force forms a second tubular portion (24) by compressing a portion of the flanged portion (108) between the second cylindrical outer surface (208) and the second cylindrical inner surface (308). In the fourth step illustrated in FIG. 12, the inner mandrel (200) and the outer mandrel (300) advance further toward each other to apply a third folding force to the remainder of the flanged portion (108). A third folding force forms a folded portion (26) by compressing the remainder of the flanged portion (108) between the concave chamfered outer surface (210) and the truncated conical inner surface (310), which positions the downstream end (30) of the second tubular portion (24) inside the cavity (32) defined by the first tubular portion (22). Finally, in the fifth step illustrated in FIG. 13, the inner mandrel (200) and the outer mandrel (300) are withdrawn from each other so that the completed tubular element (18) can be removed.

[0216] To facilitate folding of the flanged tube (106) for forming the tubular element (18), at least one of the inner mandrel (200) and the outer mandrel (300) is rotated around its longitudinal axis while applying a second folding force and a third folding force.

[0217] Those skilled in the art will understand that, depending on the length of the second cylindrical part (206) and the length of the flanged part (108), the application of the third folding force may occur before the application of the second folding force, or the application of the second folding force and the third folding force may occur simultaneously.

[0218] FIG. 14 illustrates a cross-sectional view of an aerosol generating article (400) according to a second embodiment of the present disclosure. The aerosol generating article (400) is an inhaler article such as a dry powder inhaler. The aerosol generating article (400) comprises an outer body (402) having a partially closed upstream end (404) and a partially closed downstream end (406). An upstream opening (408) is formed at the upstream end (404) of the outer body (402), and a downstream opening (410) is formed at the downstream end (406) of the outer body (402). The upstream opening (408) acts as an air inlet, and the downstream opening (410) acts as an air outlet. An airflow path extends between the upstream opening (408) and the downstream opening (410) and passes through an internal cavity (407) of the outer body (402). The upstream portion of the internal cavity (407) of the outer body (402) near the upstream end (404) accommodates a capsule-shaped substrate segment (416) containing nicotine particles.

[0219] The partially closed upstream end (404) of the outer body (402) prevents the capsule from falling out of the upstream end (404) of the outer body (102). Since the diameter of the capsule is larger than the diameter of the upstream opening (408), it cannot pass through the upstream opening (408). A tubular element (418) is provided inside the inner cavity (407) and is positioned downstream of the capsule. The tubular element (418) is fixed to the inner surface of the outer body (402) and acts as a retaining plug that restricts downstream movement of the capsule so that the capsule is maintained in the upstream portion of the inner cavity (407).

[0220] The tubular element (418) is illustrated in more detail in FIGS. 15 and FIGS. 16, which respectively show a cross-sectional view and a perspective view of the tubular element (418). The tubular element (418) is similar to the tubular element (18) described with reference to FIGS. 1 through 3, and thus similar reference numbers are used for similar parts.

[0221] The tubular element (418) differs from the tubular element (18) in that it has multiple airflow apertures (420) that extend through the folded portion (26). The multiple airflow apertures (420) are symmetrically arranged around the second tubular portion (24).

[0222] The second tubular portion (24) is in contact with the downstream end of the capsule, and the inner diameter (40) of the second tubular portion (24) is smaller than the outer diameter of the capsule, so that the movement of the capsule toward the downstream end (406) of the outer body (402) is prevented. The inner diameter (42) of the first tubular portion (22) is larger than the inner diameter (40) of the second tubular portion, so that airflow through the cavity (32) can flow substantially without restriction.

[0223] The tubular element (418) may be formed using substantially the same method as described with reference to FIGS. 4 through 14 for forming the tubular element (18). A plurality of airflow apertures (420) may be formed in the tubular body (100) before folding to form a flanged tube (106). Alternatively, the airflow apertures (420) may be formed in the folded portion (26) after the tubular element (18) is formed. The airflow apertures (420) may be formed using any suitable process. For example, the airflow apertures (420) may be formed using laser perforation.

[0224] When in use, the consumer uses an external penetration tool to penetrate the capsule through the upstream opening (408). The penetration tool is pushed into the capsule through the upstream opening (408) to create a hole in the capsule, through which nicotine particles can exit the capsule. The actual downstream movement of the capsule is restricted by the tubular element (418). The upstream end (38) of the second tubular portion (24) contacts the capsule during penetration and keeps the capsule in place, making penetration easier.

[0225] When a consumer inhales or sucks the downstream end (406) of the aerosol generating item (400), air is drawn in through the upstream portion of the internal cavity (407) of the outer body (402) that accommodates the capsule and the upstream opening (408). Nicotine particles exit the capsule and are entrained by the airflow through the outer body (402). The airflow carrying the nicotine particles passes through the cavity (32) of the tubular element (418). As the air passes from the second tubular portion (24) to the first tubular portion (22), the expansion of the cross-section of the airflow path, along with the airflow through the multiple airflow apertures (420), can cause a vortex effect that helps mix the nicotine particles with the airflow before they are inhaled into the consumer's mouth through the downstream opening (410).

[0226] The outer diameter of the second tubular part (24), which is smaller than that of the first tubular part (22), defines an annular space (426) between the outer surface of the second tubular part (24) and the inner surface of the outer body (402). The annular space (426) defines a gutter or well that collects excess nicotine particles released from the capsule when a consumer inhales the aerosol generating item (400) but not carried by the airflow. The annular space (426) also collects nicotine particles released from the capsule when the aerosol generating item (400) is moved between consumer inhalations. The annular space (426) created by the tubular element (418) acts as a barrier that reduces the possibility of nicotine particles leaking from the aerosol generating item (400) between consumer inhalations or between uses of the aerosol generating item (400).

Claims

Claim 1 An aerosol generating article comprising a plurality of elements assembled in the form of a rod, wherein the plurality of elements include a substrate element comprising an aerosol-forming substrate; and a tubular element, wherein the tubular element is A first tubular portion defining a cavity extending from the first end of the first tubular portion to the second end of the first tubular portion; A second tubular portion formed at least partially located inside the cavity defined by the first tubular portion and fluidly communicating with the cavity; and An aerosol generating article comprising a single element including a folded portion extending between the first end of the first tubular portion and the second tubular portion. Claim 2 An aerosol generating article according to claim 1, wherein the first end is an upstream end of the first tubular portion, and the folded portion extends between the upstream end of the first tubular portion and the downstream end of the second tubular portion. Claim 3 In paragraph 2, the downstream end of the second tubular portion is an aerosol generating article located inside the cavity. Claim 4 An aerosol generating article according to paragraph 3, wherein the longitudinal distance between the upstream end of the first tubular portion and the downstream end of the second tubular portion is an overlap length, and the overlap length is 0.5 mm to 3 mm, 0.75 mm to 1.5 mm, or 0.9 mm to 1.1 mm. Claim 5 An aerosol generating article according to paragraph 2, 3, or 4, wherein the upstream end of the second tubular portion is located outside the cavity. Claim 6 An aerosol generating article according to any one of paragraphs 2 to 5, wherein the upstream end of the second tubular portion is in the same plane as the upstream end of the first tubular portion. Claim 7 An aerosol generating article according to any one of claims 1 to 6, wherein the second tubular portion is entirely located inside the cavity. Claim 8 An aerosol generating article according to any one of claims 1 to 7, wherein the angle between the folded portion and the inner surface of the first tubular portion is less than 90 degrees. Claim 9 An aerosol generating article according to any one of claims 1 to 8, wherein the angle between the folded portion and the outer surface of the second tubular portion is less than 90 degrees. Claim 10 An aerosol generating article according to any one of claims 1 to 9, wherein the first tubular portion has a first length and the second tubular portion has a second length, the second length is smaller than the first length, and optionally the second length is less than 50% of the first length, less than 40% of the first length, less than 30% of the first length, less than 20% of the first length, or less than 10% of the first length. Claim 11 An aerosol generating article according to any one of claims 1 to 10, further comprising at least one airflow aperture extending through the folded portion. Claim 12 An aerosol generating article according to any one of claims 1 to 11, wherein the tubular element is formed from at least one of paper and cardboard. Claim 13 In any one of claims 1 to 12, the tubular element is 100 g / m² 2 Up to 700 g / m² 2 , preferably 100 g / m² 2 Up to 400 g / m² 2 An aerosol generating article formed from a material having a basis weight of Claim 14 An aerosol generating article according to any one of claims 1 to 13, wherein the tubular element has a length of 10 mm to 40 mm, preferably 10 mm to 30 mm, preferably 10 mm to 20 mm. Claim 15 An aerosol generating article according to any one of claims 1 to 14, further comprising a ventilation zone at a location following the tubular element.

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