Aerosol generating apparatus

Abstract

Provided is an aerosol-generating article for use in an aerosol-generating system, the aerosol-generating article comprising: an aerosol-generating segment comprising aerosol former, the aerosol-generating segment having a longitudinal direction aligned with a flowpath of the article; and an aerosol former buffer region abutting the aerosol-generating segment at a first end of the aerosol-generating segment in the longitudinal direction. The aerosol former buffer region has a length aligned with the flowpath of the article of between 0.5 and 20 mm, and the aerosol-generating segment and the aerosol former buffer region are bounded by a connecting wrapper. Either (i) the aerosol former buffer region comprises a solid substrate comprising an anti-humectant material, or (ii) the aerosol former buffer region is a void bounded by the connecting wrapper. A system comprising the aerosol-generating article and an aerosol-generating unit is also described. A use of the article and of the system is also described, as are methods of manufacture.

Description

[0001] P01587

[0002] 1

[0003] AEROSOL GENERATING APPARATUS

[0004] FIELD

[0005] The present disclosure relates to an aerosol-generating article. The invention further relates to an aerosol-generating system comprising the aerosol-generating article, uses of the aerosol-generating article and system, and methods of preparing the aerosol-generating article.

[0006] BACKGROUND

[0007] A heat-not-burn (HNB) device, also known as a heated tobacco device, is a type of aerosol-generating system in which an aerosol precursor (e.g., a solid precursor such as tobacco) is heated by a heating system to produce an aerosol that can be inhaled by the user.

[0008] The HT approach recognises that burning tobacco is not necessary to release constituents from the tobacco leaf. Rather, release is achieved at temperatures of around 350 °C or less. Because HT systems do not combust the tobacco, the lower temperatures of HT systems are expected to expose the user to emissions that have fewer chemicals and / or in smaller amounts than the smoke from a combustible cigarette. HT systems are well known in the industry, and although referred to herein as HT systems, they may also be known as heated tobacco products (HTP), Heat not Burn (HNB) and smokeless systems.

[0009] The HT class of products are easily distinguishable over e-cigarettes (or vapes), which are an alternative class of smoking substitute system based on a technology platform that uses a device to heat a pod or cartridge filled with a liquid (also termed e-liquid). Here, a primary difference is that HT systems produce an aerosol predominantly from a solid substrate (e.g. tobacco leaf), whereas in e- cigarettes, the aerosol is provided from a liquid suspension. The solid substrate may be, or may form part of, an aerosol-generating segment. The solid substrate may be referred to as a “precursor” or “aerosol-g en erati ng su bstrate” .

[0010] A typical HT system includes a HT device (i.e. including an aerosol-generating unit) and a HT consumable (i.e. an aerosol-generating article) comprising the tobacco. The consumable is disposed of and replaced at the end of a smoking session. It will be appreciated that the HT system can, herein, be interchangeably referred to as a ‘system’ and likewise, the HT device can be interchangeably referred to as a ‘device’, and also the HT consumable can be interchangeably referred to as a ‘consumable’. At a basic level, the consumable is inserted into the device to form a system, such that the user can operate the system to heat the consumable in a controlled manner to release flavours, aromas and other constituents whilst volatising the nicotine in the tobacco (without burning). A user can then draw on a mouthpiece of the consumable to draw air through the tobacco. The released constituents and volatised nicotine are entrained in the airflow to create an aerosol as it mixes and cools. The aerosol is then inhaled by the user.

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[0013] In certain HT consumables, the aerosol-generating segment also contains an aerosol former, also known as a carrier. This is typically a substance which is volatised upon heating to form an aerosol vapour. In some examples, the aerosol former includes propylene glycol (PG) and / or vegetable glycerine (VG). This may help ensure sufficient vapour is generated during use of the product to carry the volatised active substance to the user. A foil wrapper may surround the aerosol-generating segment to prevent the aerosol former migrating circumferentially out of the segment. However, it is possible that aerosol former migrates longitudinally along the consumable into neighbouring segments or out of the end of the consumable, or even through seam areas of the foil wrapper. Such leakage of aerosol former from the aerosol-generating segment may result in discoloration of the product or otherwise visually affect the consumable, and it may structurally weaken the consumable due to saturation or partial saturation of the wrapper and various segments which can lead to breakage. Discoloration and saturation or partial saturation of the wrapper also impacts user experience, for example by appearing less visually appealing or by having a “damp” feeling. There is an ongoing need to improve the experience of users of HT consumable and HT systems.

[0014] It is against this background that the present invention has been developed.

[0015] SUMMARY

[0016] At its most general, the present disclosure provides an aerosol-generating article for use in an aerosol generating apparatus to generate an aerosol that is to be consumed by a user. In some examples, the present invention provides an aerosol-generating article comprising an aerosol former buffer region to prevent, minimise, or reduce migration of aerosol former out of an aerosol-generating segment. This may suitably be when the aerosol-generating article is not in use, but is not limited thereto.

[0017] For the avoidance of doubt, the term “aerosol-generating article” refers to a consumable, such as that described in the preceding background. The term “aerosol-generating system” refers to a device and consumable used together, such as that described in the preceding background.

[0018] In a first aspect the present disclosure provides an aerosol-generating article for use in an aerosolgenerating system to generate an aerosol that is to be consumed by a user, the article comprising an aerosol-generating segment comprising an aerosol former, and an aerosol former buffer region.

[0019] The aerosol-generating segment has a longitudinal direction aligned with a flowpath of the article. A longitudinal axis of the article is also aligned with the flowpath. A longitudinal direction of one or more other segments of the article may also be aligned with the flowpath. The aerosol former buffer region may abut, for example contact, the aerosol-generating segment at a first end of the aerosol-generating segment in the longitudinal direction. The aerosol-generating segment and the aerosol former buffer region may be bounded by a connecting wrapper.

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[0022] In some examples, the aerosol former buffer region comprises a solid substrate comprising an antihumectant material. In other examples, the aerosol former buffer region is a void bounded by the connecting wrapper.

[0023] By comprising an aerosol former buffer region arranged as described herein, migration of aerosol former out of the aerosol-generating segment into neighbouring segments or out of an end of the article may be mitigated, minimised, or prevented. That is, the aerosol former buffer region may act as a buffer between the aerosol-generating segment and one or more neighbouring segments along the longitudinal axis. This may reduce, minimise, or prevent discoloration of the product due to seepage of aerosol former into the neighbouring segments or the wrapper (e.g. combining paper). This has the effect of improving the visual appeal, improving the user experience, and increasing the shelf life of the product. The inclusion of an aerosol former buffer region as described herein may additionally or alternatively reduce the likelihood of breakage of the article by reducing or preventing the neighbouring segments orthe wrapper (e.g. combining paper) from becoming saturated, partially saturated, or “damp” with the aerosol former. This has the effect of increasing the shelf life of the product, increasing the strength of the product, and improving the user experience by reducing the likelihood of a “damp” feeling.

[0024] In some examples, the aerosol-generating segment and the aerosol former buffer region are bounded by a connecting wrapper. That is, a connecting wrapper may circumscribe both the aerosol-generating segment and the aerosol former buffer region. In some examples, the connecting wrapper may hold the aerosol-generating segment and the aerosol former buffer region together, i.e. maintain, or assist in maintaining, abutment. In some examples, the wrapper is an outer wrapper of the aerosol-generating article. In some examples, the wrapper comprises paper. In some examples, the wrapper is a combining paper. In some examples, the wrapper comprises foil. In some examples, the wrapper comprises foil- lined paper. In some examples, the wrapper comprises a plastic.

[0025] The aerosol-forming material may be circumscribed by a wrapping layer e.g. a paper wrapping layer. The wrapping layer may overlie an inner foil layer or may comprise a paper / foil laminate (with the foil innermost).

[0026] Any elements (e.g. filter elements, cooling element, aerosol former buffers) upstream or downstream of the aerosol-forming material may be at least partially (e.g. entirely) circumscribed by the wrapping layer. Accordingly, the wrapping layer may alternatively be referred to as a ‘combining layer’. The wrapping layer may at least partially (e.g. entirely) circumscribe elements upstream of the terminal filter element. The terminal filter element (at the downstream end of the article / consumable) may be joined to the upstream elements forming the article / consumable by a circumscribing tipping layer e.g. a tipping paper layer. The tipping paper may have an axial length longer than the axial length of the terminal filter element such that the tipping paper completely circumscribes the terminal filter element plus the wrapping layer surrounding any adjacent upstream element.

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[0029] Any elements (e.g. filter elements, cooling element, spacer elements) may be further circumscribed by a respective plug wrap e.g. a paper plug wrap.

[0030] In some examples, the aerosol former buffer region comprises a solid substrate. In some examples, the solid substrate comprises or consists of an anti-humectant material. In some examples, the solid substrate comprises or consists of a material which reduces, minimises, or prevents humectant crossing to a neighbouring segment. In some examples, the solid substrate comprises or consists of a material comprising functional groups that do not attract or bond with alcohol (-OH) groups. In some examples, the solid substrate comprises or consists of a material without polar functional groups. In some examples, the aerosol former buffer region comprises a hydrophobic material, such as a material having a contact angle with water of more than 90 degrees at 25 °C. In this way, a hydrophilic aerosol former may be less susceptible to migrating into or through the buffer region. In some examples, the solid substrate does not absorb, or does not substantially absorb, aerosol former. In some examples, the solid substrate does absorb aerosol former. In some examples, the solid substrate comprises or consists of one or more of gelatine and / or alginate such as sodium alginate, potassium alginate, and calcium alginate; a silica, such as a hydrophobic silica (e.g. a silica not containing polar functional groups on a side-chain), a hydrophobic material; and a wax, such as beeswax and carnauba wax.

[0031] In some examples, the aerosol former buffer region comprises a solid substrate and aerosol former in an amount less than the amount of aerosol former in the aerosol-generating segment. In some examples, the amount of aerosol former in the solid substrate is non-zero. That is, in some examples, some aerosol former is present in the solid substrate. In this way, a small amount of aerosol former may be permitted to enter the aerosol former buffer region from the aerosol-generating segment, but it may not easily migrate beyond the buffer region into a neighbouring segment. That is, the aerosol former buffer region may act as a so-called “sacrificial segment”.

[0032] In some examples, where the aerosol former buffer region comprises a solid substrate and aerosol former, the solid substrate holds the aerosol former. In some examples, there may be intermolecular interactions between the aerosol former and the solid substrate, such as hydrogen bonding. In this way, migration of the aerosol former out of the buffer region may be prevented, minimised, or reduced.

[0033] In some examples, the aerosol former buffer region is downstream from the aerosol-generating segment. In this way, the aerosol former may be prevented from migrating downstream into a subsequent segment / section of the article located downstream from the aerosol-generating segment.

[0034] In some examples, the aerosol former buffer region is upstream from the aerosol-generating segment. In this way, the aerosol former may be prevented from migrating out of an end of the article, or migrating into a neighbouring upstream segment, if present.

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[0037] In some examples, the aerosol former buffer region and the aerosol-generating segment are located in an upstream half of the flowpath of the article.

[0038] In some examples, the aerosol former buffer region has a length aligned with the longitudinal axis between 0.5 and 20 mm.

[0039] In some examples, such as where the aerosol former buffer region comprises an anti-humectant material, the aerosol former buffer region has a length of at least 4 mm, such as at least 6 mm or at least 8 mm. In some examples, such as where the aerosol former buffer region comprises an antihumectant material, the aerosol former buffer region has a length of up to 15 mm, such as up to 12 mm or up to 10 mm. Any of the foregoing may be combined to form a suitable range for the length, such as between 4 and 15 mm, between 6 and 12 mm, or between 8 and 10 mm. In this way, aerosol former can be prevented or mitigated from migrating to a neighbouring segment or out of the article whilst a desired construction of the article can be achieved.

[0040] In some examples, where the aerosol former buffer region is a void, a shorter length may be suitable to maintain strength. In some examples, such as where the aerosol former buffer region is a void, the aerosol former buffer region has a length of at least 0.5 mm, such as at least 1 mm or at least 2 mm. In some examples, such as where the aerosol former buffer region is a void, the aerosol former buffer region has a length of up to 6 mm, such as up to 5 mm or up to 4 mm. Any of the foregoing may be combined to form a suitable range, such as between 0.5 and 6 mm, between 0.5 and 5 mm, or between 2 and 4 mm. In this way, aerosol former can be prevented or mitigated from migrating to a neighbouring segment or out of the article whilst a desired construction of the article can be achieved.

[0041] In some examples, the article further comprises a second segment or section positioned axially along the flowpath (i.e. the longitudinal axis) of the article. In some examples, the second segment and the aerosol-generating segment are separated by the aerosol former buffer region, for example separated only by the aerosol former buffer region. In this way, the aerosol former may be prevented or mitigated from migrating into the second segment by the aerosol former buffer region. The second segment may be downstream or upstream of the aerosol-generating segment. In some examples, the second segment is downstream of the aerosol-generating segment. In some examples, the second segment is upstream of the aerosol-generating segment. In some examples, the second segment is a filter, such as a monoacetate filter and / or a hollow bore filter. In some examples, the second segment is a cooling segment, such as a card tube.

[0042] The filter elements may be formed from materials including cellulose acetate, polypropylene tow, activated charcoal, paper, extruded plant material, and like materials. The filter elements may be circumscribed with a plug wrap, e.g. a paper plug wrap, to help maintain the form of the filter element. The filter elements may be solid. The filter elements may be hollow bore filter elements comprising one or more bores extending longitudinally through the filter element. The filter elements may retain flavorant elements, such as granules, pellets, strips, capsules or other objects.

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[0045] In some examples, the aerosol former buffer region is a void bounded by the connecting wrapper. In some examples, the aerosol former buffer region is a void circumscribed by a lumen of a tube within the wrapper. In the case where the article comprises a second segment separated by the aerosol- formed buffer region, the void may act as a gap along the flowpath (i.e. , the along the longitudinal axis) between the aerosol-generating segment and the second segment. That is, the aerosol former buffer region may be configured to maintain an axial distance between the aerosol-generating segment and the second segment.

[0046] In some examples, the aerosol former buffer region is a void comprising a spacer therein. The spacer may maintain the longitudinal length of the void along the longitudinal axis of the article. In such examples, the spacer maintains a gap between the aerosol-generating segment and a second segment of at least 0.5 mm and up to 6 mm as described elsewhere herein.

[0047] In some examples, where the aerosol former buffer region is a void within the wrapper or where the void is within a tube within the wrapper, the inner surface of the wrapper or the tube defining the void comprises a coating or lining. In some examples, the lining comprises or is a foil. In some examples, the coating or lining comprises an anti-aerosol former material. In this way, aerosol former may be prevented or mitigated from seeping / leaching / propagating through the wrapper surrounding the void.

[0048] In some examples, the aerosol-generating article comprises a second aerosol former buffer region which abuts the aerosol-generating segment at a second end in the longitudinal direction. In some examples, the aerosol-generating segment may comprise an aerosol former buffer region at both ends in the longitudinal direction. In some examples, the aerosol-generating segment is sandwiched by two aerosol former buffer regions in the longitudinal direction. In some examples, one aerosol former buffer region may be upstream of the aerosol-generating segment and one aerosol former buffer region may be downstream of the aerosol-generating segment. In this way, aerosol former may be prevented or mitigated from migrating from the aerosol-generating segment in both the upstream and downstream direction. The aerosol former buffer regions in such examples may be the same or different, for example they may differ by having two voids that differ in construction, or by having two sacrificial segments that differ e.g. in construction or material, or there may be one void and one sacrificial segment.

[0049] In some examples, the first end of the aerosol-generating segment, and optionally a second end opposite the first end, comprises a coating or lining, optionally wherein the coating or lining comprises an anti-aerosol former material. The coating or lining may be as described above.

[0050] In some examples, the aerosol former buffer region is free of, or substantially free of, an active compound when not in use (i.e. before it has been used / consumed). In this way, the aerosol former buffer region may be distinct from the aerosol-generating segment (and any other active compoundcontaining segment).

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[0053] The aerosol-generating article is a HT consumable for use in an aerosol-generating system (a HT device) for generating an aerosol that is to be consumer by a user. The general structure of such articles is known to those in the art. The aerosol-generating article may be elongate. In some examples, the aerosol-generating article comprises a longitudinal axis. The longitudinal axis may define or align with a flowpath of the aerosol to be generated in use. The aerosol may move from an upstream position in the flowpath to a downstream position in the flowpath, as it is consumer by a user. That is, the terms “upstream” and “downstream” may be defined in respect of a direction of flow in the flowpath e.g. downstream may indicate the direction towards a mouthpiece for consumption by the user. The aerosolgenerating article may have any desired cross-sectional shape, and in some examples may be generally cylindrical or prismatic, such as cuboidal. In some examples, the aerosol-generating article is generally cylindrical. In some examples, an outer shape of the article may be defined (e.g. circumscribed) by a wrapper which covers the circumferential surface of a cylindrical or prismatic shape.

[0054] The aerosol-generating article may comprise an aerosol-generating segment. In some examples, the aerosol-generating segment is positioned within a wrapper of the article. In some examples, the aerosolgenerating segment is positioned at an end of the longitudinal axis of the article, such as an upstream end. In some examples, the aerosol-generating segment is positioned in close proximity to at an end of the longitudinal axis of the article, such as an upstream end. In some examples, the aerosol-generating segment may be positioned in an upstream half of the article. In some examples, there is a terminal segment between the aerosol-generating segment and an extreme of an end of the aerosol-generating article, such as the upstream end. In some examples, the aerosol-generating segment is positioned at an extreme of an end of the aerosol-generating article, such as the most upstream end.

[0055] The aerosol-generating article may comprise a mouthpiece. In some examples, the mouthpiece is positioned within the wrapper of the article. In some examples, the mouthpiece is positioned at an opposite end of the longitudinal axis of the article to the aerosol-generating segment. In some examples, the mouthpiece may be positioned at a downstream end. In some examples, the mouthpiece is positioned in close proximity to at an opposite end of the longitudinal axis of the article to the aerosolgenerating segment. In some examples, the mouthpiece may be positioned in a downstream half of the longitudinal axis of the article. In some examples, there is one or more additional segment, section, or region between the aerosol-generating segment and the mouthpiece. In some examples, an additional segment, section, or region may be an aerosol former buffer region, a cooling segment, or a filter (e.g. a hollow bore filter, e.g. a filter having a bore with diameter 3.5 mm).

[0056] In some examples, the aerosol-generating article is a heat-not-burn (HNB) consumable.

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[0059] In some examples, the aerosol-generating article further comprises one or more of: a mouthpiece segment at a downstream end of the aerosol-generating article; a hollow bore filter located downstream of the aerosol-generating substrate; and a cooling segment (e.g. a cardboard tube) located downstream ofthe aerosol-generating substrate.

[0060] The aerosol-generating segment is or comprises a solid aerosol-generating material. The aerosolgenerating segment comprises an aerosol former which, upon application of heat, can generate an aerosol to be consumed by a user. In some examples, the aerosol former is a liquid aerosol former. The form and composition of a typical aerosol-generating segment are known to those in the art. In some examples, the aerosol-generating segment may comprise tobacco. In some examples, the aerosol-generating segment is tobacco-free. The aerosol-generating segment comprises an aerosol former. The aerosol-generating segment is abutted by an aerosol former buffer region.

[0061] The aerosol-forming material may comprise plant material.

[0062] The plant material may comprise or be formed of tobacco. Any type of tobacco may be used, including, but is not limited to, flue-cured tobacco, burley tobacco, Virginia tobacco, Maryland Tobacco, dark-air cured tobacco, oriental tobacco, dark-fired tobacco, perique tobacco, rustica tobacco. This also includes blends ofthe above mentioned tobaccos. Any suitable parts of the tobacco plant may be used, including leaves, stems, roots, bark, seeds and flowers. The tobacco may comprise one or more of leaf tobacco, stem tobacco, tobacco powder, tobacco dust, tobacco derivatives, expanded tobacco, homogenised tobacco, shredded tobacco, extruded tobacco, cut rag tobacco and / or reconstituted tobacco (e.g. slurry recon or paper recon). For example, the aerosol-forming material may comprise a gathered sheet of homogenised (e.g. paper / slurry recon) tobacco or gathered shreds / strips formed from such a sheet.

[0063] The tobacco may be processed tobacco, steam treated stems or shredded dried stems. The tobacco material may be fermented, cured, uncured, toasted, or otherwise pre-treated. The tobacco may be unprocessed and / or untreated.

[0064] The aerosol-forming material may be absent of tobacco and / or nicotine.

[0065] The plant material may comprise at least one plant material selected from the list including Amaranthus dubius, Arctostaphylos uva-ursi (Bearberry), Argemone mexicana, Arnica, Artemisia vulgaris, Yellow Tees, Galea zacatechichi, Canavalia maritima (Baybean), Cecropia mexicana (Guamura), Oestrum noctumum, Cynoglossum virginianum (wild comfrey), Cytisus scoparius, Damiana, Entada rheedii, Eschscholzia califomica (California Poppy), Fittonia albivenis, Hippobroma longi flora, Humulus japonica (Japanese Hops), Humulus lupulus (Hops), Lactuca virosa (Lettuce Opium), Laggera alata, Leonotis leonurus, Leonurus cardiaca (Motherwort), Leonurus sibiricus (Honeyweed), Lobelia cardinalis, Lobelia inflata (Indian-tobacco), Lobelia siphilitica, Nepeta cataria (Catnip), Nicotiana species (Tobacco), Nymphaea alba (White Lily), Nymphaea caerulea (Blue Lily), Opium poppy,

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[0068] Passiflora incamata (Passionflower), Pedicularis densiflora (Indian Warrior), Pedicularis groenlandica (Elephant's Head), Salvia divinorum, Salvia dorrii (Tobacco Sage), Salvia species (Sage), Scutellaria galericulata, Scutellaria lateriflora, Scutellaria nana, Scutellaria species (Skullcap), Sida acuta (Wireweed), Sida rhombi folia, Silene capensis, Syzygium aromaticum (Clove), Tagetes lucida (Mexican Tarragon), Tarchonanthus camphoratus, Tumera diffusa (Damiana), Verbascum (Mullein), Zamia latifolia (Maconha Brava) together with any combinations, functional equivalents to, and / or synthetic alternatives of the foregoing.

[0069] The aerosol-forming material may comprise one or more additives selected from vapour generators, carrier agents, humectants, flavourants, fillers, aqueous / non-aqueous solvents and binders.

[0070] The aerosol-forming material may comprise propylene glycol (PG) and / or vegetable glycerin (VG). Propylene glycol (PG) and vegetable glycerin (VG) are typically used as base materials that act as aerosol generators (alternatively referred to as aerosol-formers), carrier agents, and / or humectants. The aerosol-forming material may comprise, alternatively or in addition, other substances that function as one or more of aerosol generators, carrier agents, and humectants.

[0071] The liquid aerosol former content of the aerosol-forming material may have a lower limit of at least 5 wt %, such as at least 10 wt %. The liquid aerosol former content of the combustible material of the smoking body may have an upper limit of at most 50 % by weight of the plant material, such as at most 40 wt % .

[0072] Flavourants may be provided in solid form, liquid form, gel form, or a combination thereof. Flavourants may include one or more of menthol (e.g. peppermint (mentha piperita), spearmint (mentha spicata), wild mint (Mentha Arventis), horse mint (Mentha longifolia), pineapple mint (Mentha suaveolens variegata), applemint (Mentha suaveolens), pennyroyal (Mentha pulegium)), liquorice, chocolate / cocoa, fruit flavour (including e.g. apple, citrus, cherry, banana (Isoamyl acetate)), rose, vanilla (Ethylvanillin), spice (e.g. ginger, clove, cinnamon, star anise), tobacco extract / flavour, marijuana, hemp, cannabinoid compounds, citronella, orange, lemon, geraniol, thyme, fennel, green tea, black tea, coffee, salvia dorrii, salvia, passiflora incarnata, arctostaphylos uva-ursi, lobelia inflata, matcha, Yerba mate, lemon grass, flax, cedar wood, coumarin, helio, eucalyptus, ginkgo biloba, hazel, hibiscus, laurel, chamomile, rosemary, lavender, rooibos, or combinations thereof. The flavourant may be evenly dispersed throughout the aerosol-forming material or may be provided in isolated locations and / or varying concentrations throughout the aerosol-forming material.

[0073] The cannabinoid compounds may be selected from the non-exhaustive list comprising: tetrahydrocannabinol (THC), cannabidiol (CBD), cannabinol (CBN).

[0074] Fillers can strengthen the aerosol-forming material. Fillers may comprise fibrous (non-tobacco) fillers such as cellulose fibres, lignocellulose fibres (e.g. wood fibres), jute fibres and combinations thereof.

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[0077] Binders can act to bind together the components forming the aerosol-forming material. Binders may comprise starches and / or cellulosic binders such as methyl cellulose, ethyl cellulose, hydroxy propyl cellulose, hydroxyethyl cellulose and methyl cellulose, gums such as xanthan, guar, arabic and / or locust bean gum, organic acids and their salts such as alginic acid / sodium alginate, agar and pectins.

[0078] The aerosol-generating segment may be contained within the wrapper of the aerosol-generating article. In some examples, the aerosol-generating segment is wrapped with a foil; in some examples, the wrapper is or comprises a foil. In some examples, the aerosol-generating segment is wrapped with paper; in some examples, the wrapper is or comprises paper, such as combining paper. In some examples, the aerosol-generating segment is wrapped with card; in some examples, the wrapper may be or comprise card. In some examples, the wrapper is a paper or card tube. In some examples, the wrapper is a paper with a foil lining. In some examples, the wrapper comprises an inner foil wrapper around a part of the length of the article. In some examples, the wrapper comprises an outer paper wrapper around a part of or the entire length of the article.

[0079] In some examples, the aerosol-generating segment is cylindrical or prismatic in shape, such as cylindrical or cuboidal. In some examples, the aerosol-generating segment comprises a longitudinal direction. The longitudinal direction of the segment may be aligned with the flowpath (i.e., the longitudinal axis) of the article. In some examples, the aerosol-generating segment may be centrally aligned with the longitudinal axis of the article.

[0080] In some examples, the aerosol-generating segment has a length in the longitudinal axis of between 4 mm and 50 mm. In some examples, the length is 5 mm or more, 7.5 mm or more, 10 mm or more, 11 mm or more, 12 mm or more, 15 mm or more, 17.5 mm or more, 20 mm or more, 25 mm or more, or 30 mm or more. In some examples, the length is 40 mm or less, 35 mm or less, 30 mm or less, 25 mm or less, 20 mm or less, 17.5 mm or less, 15 mm or less, 14 mm or less, 13 mm or less, 12 mm or less, 10 mm or less, or 7.5 mm or less. Any of the foregoing may be combined to form a suitable range, such as between 5 and 40 mm, or between 10 and 15 mm. In some examples, the length is about 12 mm.

[0081] The aerosol former is also known as a humectant. This is typically a substance which is volatised upon heating to form an aerosol vapour. In some examples, the aerosol former may include propylene glycol (PG) and / or vegetable glycerine (VG). In some examples, the aerosol former comprises or consists of PG. In some examples, the aerosol former comprises or consists of VG. In some examples, the aerosol former comprises or consists of a mixture of PG and VG. Other examples of aerosol former include, but are not limited to, polyethylene glycol (PEG) and medium chain triglycerides (MCT). In some examples, the aerosol former comprises one or more selected from: PG, VG, PEG, and MCT.

[0082] In some examples, the aerosol former is a liquid at room temperature. That is, the aerosol-generating segment may comprise a solid substrate doused with or loaded with the aerosol former. In some examples, the solid substrate absorbs the liquid aerosol former.

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[0085] The aerosol former buffer region (AFBR) is a region or segment of the aerosol-generating article which abuts the aerosol-generating segment. In some examples, the AFBR abuts an end of the aerosolgenerating segment, such as an end in the longitudinal direction of the aerosol-generating segment. In some examples, along the flowpath of the article (i.e., in the longitudinal axis of the article), the AFBR may be adjacent to the aerosol-generating segment. The AFBR may prevent, minimise, or mitigate migration of aerosol former from the aerosol-generating segment into one or more other segments or sections in the aerosol-generating article. This may be when the article is not in use. In some examples, the AFBR may prevent, minimise, or mitigate migration of aerosol former from the aerosol-generating segment along the flowpath of the article. The AFBR may not substantially limit the flow of aerosol (e.g. volatised substances) along the flowpath of the article. In some examples, the aerosol former may be able to pass through the AFBR when volatised. In some examples, aerosol or volatised substances may be able to move along the flowpath through the AFBR, such as from an upstream end of the AFBR to a downstream end of the AFBR. In some examples, the AFBR may comprise one or more passages along (or parallel to) the longitudinal axis. In some examples, the AFBR may be porous or hollow. In some examples, an upstream end of the AFBR and a downstream end of the AFBR may be in fluid communication through the AFBR.

[0086] Forthe avoidance of doubt, reference herein to the AFBR mitigating, minimising, or preventing migration of aerosol former is in reference to the aerosol former when the article is not in use or has not been consumed. That is, the aerosol former has not been heated orvolatised. In some examples, the aerosol former is a liquid, a suspension, or is adhered to the aerosol-generating segment. In some examples, the AFBR enacts its primary function after the article has been manufactured but before it has been consumed, such as when the article is being stored (e.g. before or after purchase).

[0087] The AFBR may abut an end of the aerosol-generating segment. That is, the AFBR may be positioned in contact with the aerosol-generating segment at an end of the segment in its longitudinal direction. In some examples, the AFBR and the aerosol-generating segment are simultaneously aligned with the longitudinal axis of the article. In some examples, the AFBR and the aerosol-generating segment have a common cross-section, for example a common axial cross-section, such as a transverse cross-section (i.e. one perpendicular to the longitudinal axis). In some examples, the AFBR and the aerosolgenerating segment have a common transverse cross-section which is a circle when they are both cylindrical. In some examples, the AFBR and the aerosol-generating segment are bounded by a connecting wrapper, for example they may be held together by the wrapper. In some examples, the AFBR and the aerosol-generating segment are bounded by (e.g. held together by) an outer wrapper of the article (e.g., combining paper). In some examples, the AFBR and the aerosol-generating segment are held together by a foil, such as one surrounding the aerosol-generating segment. In some examples, the AFBR and the aerosol-generating segment are held together by an adhesive, for example at their abutting ends. In some examples, the AFBR and aerosol-generating segment are held together by adhesion between the abutting ends, in the absence of an additional adhesive, e.g. due to the

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[0089] 12

[0090] “stickiness” of the aerosol-generating segment. In some examples, the AFBR has a transverse crosssection which matches a transverse interior cross-section (e.g. not including the outer wrapper) of the aerosol-generating article. In some examples, when the aerosol-generating article is cylindrical or prismatic, the AFBR may be correspondingly cylindrical or prismatic, e.g. with their corresponding transverse cross-sections which differ only in the presence / absence of the wrapper of the article (though their longitudinal dimensions may differ).

[0091] The AFBR may be positioned upstream or downstream of the aerosol-generating segment. In some examples, the AFBR is upstream of the aerosol-generating segment, for example to prevent or mitigate migration of the aerosol former out of an upstream end of the article. In some examples, the AFBR is downstream of the aerosol-generating segment, for example to prevent or mitigate migration of the aerosol former into a downstream segment or section of the article. In some examples, the aerosolgenerating article comprises two AFBRs. In some examples, the aerosol-generating article may comprise an upstream AFBR and a downstream AFBR. In some examples, the aerosol-generating segment may be “sandwiched” by two AFBRs. In some examples, an upstream AFBR abuts an upstream end of the aerosol-generating segment in the longitudinal direction. In some examples, a downstream AFBR abuts a downstream end of the aerosol-generating segment in the longitudinal direction. In some examples, the upstream and the downstream AFBR are substantially the same. In some examples, the upstream and the downstream AFBR are not the same. In some examples, the upstream and downstream AFBR may have a different form, shape, size, or material. In some examples, each of the upstream and downstream AFBR may independently be an AFBR as described herein.

[0092] In some examples, the AFBR separates the aerosol-generating segment from a second segment positioned axially along the flowpath (i.e. the longitudinal axis) of the article. In some examples, the AFBR abuts the aerosol-generating segment at one of its ends and abuts the second segment at its other end. In some examples, the AFBR is “sandwiched” between the aerosol-generating segment and the second segment. In some examples, the AFBR is held in position by the presence of the aerosolgenerating segment and the second segment. In some examples, the AFBR prevents or mitigates migration of aerosol former from the aerosol-generating segment to the second segment. In some examples, the AFBR prevents migration of aerosol former from the aerosol-generating segment to the second segment. In some examples, the AFBR mitigates or slows migration of aerosol former from the aerosol-generating segment to the second segment.

[0093] In some examples, the AFBR is a void. In some examples, the AFBR is a void bounded by a wrapper (e.g. combining paper or foil) of the article. In some examples, the void is within the wrapper. In some examples, the AFBR may be described as hollow. In some examples, the AFBR is a void defined (i.e. circumscribed) by a portion of the wrapper. In some examples, the dimensions of the void (e.g. the circumferential boundary of the void) are defined by (i.e., the void is bounded by) the inner surface of the wrapper. In some examples, the dimensions of the void are defined by (i.e., the void is bounded by)

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[0095] 13 a portion of the wrapper and an end face of the aerosol-generating segment. In some examples, the dimensions of the void are defined by (i.e., the void is bounded by) a portion of the wrapper, an end face of the aerosol-generating segment, and an end face of a second segment. In some examples, the AFBR is an empty segment within a portion of the wrapper of the article. In some examples, the void is cylindrical or prismatic with substantially the same transverse cross-section as the aerosol-generating segment. In some examples, the AFBR may be a cavity within the article (e.g. within the wrapper). In some examples, the void is empty. In some examples, the AFBR is a hollow section of the article. In some examples, the void is a cylindrical cavity. In some examples, the cylindrical cavity has a diameter of 2 mm or more, 3 mm or more, 4 mm or more, 5 mm or more, 6 mm or more, 7 mm or more, 8 mm or more, 9 mm or more, or 10 mm or more. In some examples, the cylindrical cavity has a diameter of 15 mm or less, 12 mm or less, 11 mm or less, 10 mm or less, 8 mm or less, 7 mm or less, 6 mm or less, 5 mm or less, or 4 mm or less. In some examples, the cylindrical cavity has a diameter of between 5 and 8 mm, such as about 5 mm, about 6 mm, about 7 mm, or about 8 mm.

[0096] In some examples, the AFBR comprises a tube. In some examples, the interior of the tube defines (i.e. circumscribes) a void. In other words, in some examples, the AFBR is a void defined by (i.e. bounded by) a tube. In some examples, the void is the lumen of the tube. In some examples, the tube is made from paper, card, plastic, foil, or foil-lined paper or card. In some examples, the tube has a diameter (e.g. an outer diameter) substantially the same as the diameter of the aerosol-generating segment. In some examples, the lumen of the tube has a diameter smaller than the diameter of the aerosolgenerating segment. In some examples, the lumen of the tube has a diameter of 2 mm or more, 3 mm or more, 4 mm or more, 5 mm or more, 6 mm or more, 7 mm or more, 8 mm or more, 9 mm or more, or 10 mm or more. In some examples, the lumen of the tube has a diameter of 15 mm or less, 12 mm or less, 11 mm or less, 10 mm or less, 8 mm or less, 7 mm or less, 6 mm or less, 5 mm or less, or 4 mm or less. Any of the foregoing may be combined to form a suitable range, such as between 5 and 8 mm. In some examples, the lumen of the tube has a diameter of about 5 mm, about 6 mm, about 7 mm, or about 8 mm. In some examples, an end of the tube abuts the aerosol-generating segment in the longitudinal direction. In some examples, the tube and the aerosol-generating segment are bounded (e.g. held together) by the wrapper. In some examples, the tube has a wall with a thickness of 2 mm or less, 1 .5 mm or less, 1 mm or less, 0.75 mm or less, 0.5 mm or less, 0.25 mm or less, 0.1 mm or less, or 0.05 mm or less. In some examples, the wall has a thickness of about 0.05 mm, about 0.1 mm, about 0.2 mm, about 0.25 mm, about 0.3 mm, about 0.4 mm, about 0.5 mm, about 0.75 mm, about 1 mm, about 1 .25 mm, about 1 .5 mm, about 1 .75 mm, or about 2 mm. Any of the foregoing may be combined to form a suitable range, such as between about 0.05 and 2 mm, between about 0.1 and 0.5 mm or between about 0.2 and 1 mm.

[0097] For the avoidance of doubt, when the AFBR is a void which abuts the aerosol-generating segment, the void is immediately adjacent to the aerosol-generating segment at a first end of the segment in the longitudinal direction. That is, at the first end, no other segment abuts the aerosol-generating segment. That is, at the first end, there is either a gap (i.e. a void) between the aerosol-generating segment and

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[0099] 14 a second segment, or there is nothing within the wrapper between the aerosol-generating segment and an end of the article. In the case where there is nothing within the wrapper between the aerosolgenerating segment and an end of the article, the aerosol-generating segment is effectively inset from the end of the article (e.g. there is a recess at the end of the article).

[0100] In some examples, where the article comprises a second segment positioned axially along the longitudinal axis of the article (e.g. downstream), the void acts as a gap between the aerosol-generating segment and the second segment. The gap is a gap in the longitudinal direction. The aerosol-generating segment and the second segment may still be connected by another means, such as the wrapper.

[0101] In some examples, the AFBR is a void comprising a spacer. In some examples, the void may comprise a spacer in the examples where the article comprises a second segment separated from the aerosolgenerating segment by said AFBR. In some examples, the spacer maintains a length of the void. In some examples, the spacer maintains a gap between the aerosol-generating segment and the second segment. In some examples, the spacer provides strength to the article. In some examples, the spacer has a longest dimension equal to or less than the length of the AFBR. In some examples, the spacer has a longest dimension equal to the length of the AFBR. In some examples, the spacer is attached to the aerosol-generating segment. In some examples, the spacer is attached to the second segment. In some examples, the spacer is loose within the void. In some examples, the spacer is made of one or more selected from: paper, card, cardboard, foil, cellulose, and plastic. In some examples, the spacer is a rod. In some examples, the rod has a substantially smaller diameter than the aerosol-generating segment or aerosol-generating article. In some examples, the rod has a cross-sectional diameter of between 0.5 mm and 6 mm, for example between 1 mm and 5 mm, for example between 2 mm and 4 mm. In some examples, the rod has a diameter of about 1 .5 mm, about 2 mm, about 2.5 mm, about 2.75 mm, about 3 mm, about 3.5 mm, or about 4 mm. In some examples, the spacer is a tube. In some examples, the tube has a substantially smaller diameter than the aerosol-generating segment or aerosol-generating article. In some examples, the tube has a substantially similar diameter to the aerosol-generating segment; In some examples, the tube has a generally similar outer shape and size as the void. In some examples, the tube defines the void (i.e. , the void is the space inside the tube, i.e. the lumen). In some examples, the spacer is positioned centrally within the void. In some examples, the spacer may be aligned with the longitudinal axis of the article. In some examples, the spacer is parallel to the longitudinal axis of the article. In some examples, the spacer is parallel to, but not aligned with (i.e. not incident with), the longitudinal axis of the article. In some examples, the spacer is attached to the wrapper of the article. In some examples, the length of spacer is smaller than the length of the void. In some examples, the cross-section of the spacer is smaller than the cross-section of the void. In some examples, the diameter of the spacer is smaller than the diameter of the void.

[0102] In some examples, the AFBR is a void not comprising a spacer. In some examples, the void is maintained by the positions of the aerosol-generating segment and the second segment being maintained. In some examples, the position of the aerosol-generating segment and / or of the second

[0103] 008519555 segment is maintained by an adhesive (e.g. an adhesive applied to the wrapper). In some examples, the position of the aerosol-generating segment and / or of the second segment is maintained by a friction fit by the connecting wrapper. In some examples, the position of the aerosol-generating segment and / or of the second segment is maintained by said segment(s) being adhered to the wrapper (e.g. by using an adhesive or due to intrinsic adhesiveness of the segment(s)).

[0104] In some examples, the void is positioned upstream of the aerosol-generating segment. In some examples, the void acts as a terminal segment at the upstream end of the article. In some examples, at the upstream extremity of the article there is an open void, and the aerosol-generating segment is downstream from the void. The open void may have a circumferential surface defined by the wrapper, and only one end face which is defined by the upstream end of the aerosol-generating segment.

[0105] In some examples, such as where the AFBR is a void defined by (i.e. bounded by) a portion of the wrapper or by a tube, the internal surface of the portion of the wrapper or the tube comprises a coating or a lining. In some examples, one or both longitudinal ends of the AFBR comprise a coating or a lining. In some examples, the end of the AFBR which abuts the aerosol-generating segment comprises a coating or a lining. In some examples, the end of the AFBR which abuts a second segment comprises a coating or a lining. In some examples, the longitudinal end of the aerosol-generating segment which abuts the AFBR comprises a coating or a lining.

[0106] The terms coating and lining may be used interchangeably herein. In some examples, the coating comprises an anti-aerosol former substance (anti-humectant material), such as gelatine and / or alginate. In some examples, the coating is or comprises a hydrophobic coating. In some examples, the coating comprises hydrophobic silica. In some examples, the coating comprises a wax, such as beeswax or carnauba wax. In some examples, the anti-humectant material comprises an oil. In some examples, the coating comprises an alginate (e.g. sodium alginate, potassium alginate, or calcium alginate). In some examples, the coating comprises gelatine. In some examples, the coating is polymeric. In some examples, the coating is a plastic. In some examples, the coating is a vapour-selective membrane (i.e. a membrane which is permeable to vapour but not liquid). In some examples, the coating is an air- permeable porous membrane. In some examples, the coating (i.e. lining) is a foil. In some examples, the coating is a layer of foil (e.g. a foil lining). In some examples, the foil may be aluminium foil. In some examples, the coating or lining has a thickness of at least 20 nm, at least 50 nm, at least 100 nm, at least 200 nm, at least 250 nm, at least 300 nm, at least 350 nm, at least 400 nm, or at least 500 nm. In some examples, the coating or lining has a thickness of up to 500 pm, up to 450 pm, up to 400 pm, up to 350 pm, up to 300 pm, up to 250 pm, or up to 200 pm. Any of the foregoing may be combined to form a suitable range, such as between 20 nm and 500 pm, between 50 nm and 400 pm, between 100 nm and 250 pm, or between 500 nm and 200 pm. In some examples, the lining is a mesh material, for example made of a cloth material. In some examples, the coating comprises a material having a contact angle with water of greater than 90 degrees at 25 °C, for example greater than 100, 110, 120, or 130

[0107] 008519555 16 degrees. In some examples, the AFBR is a void comprising a spacer and a lining or coating on the inner surface of the surrounding tube or wrapper.

[0108] In some examples, such as where the AFBR is a void, the internal surface of the wrapper or the tube has been functionally modified with anti-humectant or hydrophobic groups, such as hydrocarbons, alkyl groups, fatty acids, hydrophobic amino acids, silica, or silicones.

[0109] In some examples, such as where the AFBR is a void, the length of the AFBR is between 0.5 mm and 10 mm. In some examples, the AFBR is a void with a length of 0.5 mm or more, 0.75 mm or more, 1 mm or more, 1 .5 mm or more, 2 mm or more, 2.5 mm or more, 3 mm or more, 4 mm or more, or 5 mm or more. In some examples, the AFBR is a void with a length of 10 mm or less, 9 mm or less, 8 mm or less, 7.5 mm or less, 7 mm or less, 6 mm or less, 5 mm or less, 4 mm or less, 3 mm or less, 2.5 mm or less, 2 mm or less, or 1 mm or less. Any of the foregoing may be combined to form a suitable range, such as between 0.5 and 10 mm, between 1 and 5 mm, or between 2 and 7 mm.

[0110] In some examples, the AFBR comprises or consists of anti-aerosol former material. An anti-aerosol former material or substance is one which typical aerosol formers (e.g. PG and VG) do not readily adhere to or cannot pass through. In some examples, anti-aerosol former materials may be hydrophobic. In some examples, the AFBR is not a void. In some examples, the AFBR comprises or is a solid segment. In some examples, the AFBR comprises or is a porous solid segment. In some examples, the anti-aerosol former material is an anti-humectant material. In some examples, the antiaerosol former material is a hydrophobic material. In some examples, the anti-aerosol former material comprises a silica, such as a hydrophobic silica. In some examples, the anti-aerosol former material comprises a wax. In some examples, the anti-aerosol former material comprises an alginate (e.g. sodium alginate). In some examples, the anti-aerosol former material comprises a gelatine. In some examples, such as where the AFBR comprises or consists of anti-aerosol former material, the length of the AFBR is between 5 mm and 15 mm, such as between 7.5 mm and 12.5 mm, such as between 8 mm and 10 mm.

[0111] In some examples, the AFBR acts as a “sacrificial segment”. A sacrificial segment may be a segment into which an amount of aerosol former may migrate, for example a limited amount of aerosol former. In some examples the aerosol former migrates into the sacrificial segment instead of an alternative or subsequent neighbouring segment. In some examples, the sacrificial segment comprises a material which the aerosol former adheres to. In some examples, the sacrificial segment absorbs aerosol former. In some examples, aerosol former adsorbs to the sacrificial segment. In some examples, the sacrificial segment is generally impermeable to liquid aerosol former but is permeable to volatised or gaseous aerosol former. In some examples, the sacrificial segment comprises or consists of anti-aerosol former material, as described above. In some examples, the sacrificial segment comprises or consists of the anti-humectant material. In some examples, the sacrificial segment comprises or consists of cellulose acetate. In some examples, the sacrificial segment comprises or consists of cotton.

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[0114] In some examples, the sacrificial segment comprises an amount of aerosol former (i.e. a non-zero amount). In some examples, the amount of aerosol former is less than the amount of aerosol former contained in the aerosol-generating segment. In some examples, the concentration of aerosol former is less than the concentration of aerosol former contained in the aerosol-generating segment. In some examples, the volume of aerosol former is less than the volume of aerosol former contained in the aerosol-generating segment. In some examples, the mass of aerosol former is less than the mass of aerosol former contained in the aerosol-generating segment. In some examples, the sacrificial segment does not contain aerosol former. In some examples, upon manufacture, the sacrificial segment may be substantially free of aerosol former. However, in some examples, over time (e.g. during storage) an amount of aerosol former may migrate into the sacrificial segment from the aerosol-generating segment. In some examples, upon manufacture, an amount of aerosol former is present in the sacrificial segment.

[0115] In some examples, the AFBR is wrapped or surrounded with an aerosol former barrier, for example circumferentially wrapped or surrounded. The barrier prevents seepage of aerosol former from the AFBR into the wrapper. In some examples, the aerosol former barrier comprises a sheet, for example a foil sheet or a sheet of foil-lined paper. In some examples, the aerosol former barrier comprises an anti-aerosol former material. In some examples, the aerosol former barrier comprises an anti-humectant material. In some examples, the aerosol former barrier comprises paper or card loaded with an antiaerosol former material. In some examples, the aerosol former barrier circumferentially surrounds the AFBR and at least part of the aerosol-generating segment.

[0116] In some examples, the AFBR is or comprises a solid segment, the solid segment comprising one or more bore holes which provide a passage along the flowpath of the article. In some examples, the one or more bole holes are generally parallel to the longitudinal axis of the article. In this way, a pressure drop along the flowpath can be avoided in use.

[0117] The AFBR has a length of between 0.5 mm and 20 mm. The length is measured along or parallel to the longitudinal axis of the article. In some examples, the length is the longitudinal dimension of a cylindrical or prismatic AFBR.

[0118] The length of the AFBR is 0.5 mm or more. In some examples, the length is 0.75 mm or more, 1 mm or more, 1 .5 mm or more, 2 mm or more, 2.5 mm or more, 3 mm or more, 4 mm or more, 5 mm or more, 6 mm or more, 7 mm or more, 7.5 mm or more, 8 mm or more, 9 mm or more, 10 mm or more, 11 mm or more, 12 mm or more, 12.5 mm or more, 13 mm or more, 14 mm or more, 15 mm or more, 16 mm or more, 17 mm or more, 18 mm or more, or 19 mm or more. In some examples, the length is 1 mm or more. In some examples, the length is 2 mm or more. In some examples, the length is 5 mm or more. In some examples, the length is 8 mm or more.

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[0120] 18

[0121] The length of the AFBR is 20 mm or less. In some examples, the length is 19 mm or less, 18 mm or less, 17 mm or less, 16 mm or less, 15 mm or less, 14 mm or less, 13 mm or less, 12.5 mm or less, 12 mm or less, 11 mm or less, 10 mm or less, 9 mm or less, 8 mm or less, 7.5 mm or less, 7 mm or less, 6 mm or less, 5 mm or less, 4 mm or less, 3 mm or less, 2.5 mm or less, 2 mm or less, or 1 mm or less. In some examples, the length is 12.5 mm or less. In some examples, the length is 10 mm or less. In some examples, the length is 7.5 mm or less. In some examples, the length is 5 mm or less.

[0122] In some examples the length of the AFBR is about 1 mm, about 2 mm, about 3 mm, about 4 mm, about 5 mm, about 6 mm, about 7 mm, about 8 mm, about 9 mm, about 10 mm, about 11 mm, about 12 mm, about 13 mm, about 14 mm, about 15 mm, about 16 mm, about 17 mm, about 18 mm, about 19 mm, or about 20 mm. In some examples, the length is about 2 mm. In some examples, the length is about 3 mm. In some examples, the length is about 4 mm. In some examples, the length is about 5 mm. In some examples, the length is about 8 mm. In some examples, the length is about 9 mm. In some examples, the length is about 10 mm.

[0123] In some examples, the article comprises two or more sequentially abutting AFBRs. In some examples, a first AFBR abuts the aerosol-generating segment, as previously described, and a second AFBR abuts the first AFBR. In some examples, in the longitudinal direction, the first AFBR is adjacent to the aerosol-generating segment, and the second AFBR is adjacent to the first AFBR. In some examples, the first AFBR is “sandwiched” between the aerosol-generating segment and the second AFBR. In some examples, the first and second AFBR are both upstream of the aerosol-generating segment or are both downstream of the aerosol-generating segment. In some examples, the article comprises a third AFBR which abuts the second AFBR (e.g. in a similar way to how the second AFBR abuts the first AFBR). The two or more sequentially abutting AFBRs may be different in shape, material, or form. In some examples, the first AFBR is a void, and the second AFBR is a sacrificial segment. In some examples, the first AFBR is a sacrificial segment, and the second AFBR is a void. In some examples, the first AFBR and the second AFBR are both sacrificial segments, with the two sacrificial segments being different in composition, shape, and / or structure. In some examples, each AFBR may independent be any AFBR as described herein. In addition to the two or more sequentially abutting AFBRs, the article may also comprise a further AFBR abutting the opposite end of the aerosolgenerating segment.

[0124] In some examples, the anti-humectant material of the AFBR is or comprises a perforated barrier or permeable membrane. In some examples, the perforated barrier or permeable membrane spans the transverse cross-section of the flowpath of the article (e.g. the transverse cross-section of the interior of the article, bounded by the wrapper). In some examples, the barrier or membrane prevents or mitigates migration of liquid aerosol former along the flowpath (i.e. parallel to the longitudinal axis) but permits movement of aerosol. That is, an aerosol may pass through the perforated barrier or permeable membrane along the flowpath. In some examples, the perforated barrier comprises a perforated sheet. In some examples, the sheet is foil, card, paper, or plastic. In some examples, the permeable membrane

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[0126] 19 is or comprises a polymeric membrane. In some examples, the perforated barrier or permeable membrane has a thickness of between 0.1 and 3 mm, such as between 0.5 and 1 mm.

[0127] In some examples, the AFBR is not a filter. In some examples, the AFBR is not a hollow-bore filter. In some examples, the AFBR does not comprise cellulose acetate. In some examples, the AFBR is not a cellulose acetate filter. In some examples, the AFBR does not comprise activated charcoal. In some examples, the AFBR does not comprise paper. In some examples, the AFBR is free of, or substantially free of, tobacco. In some examples, the AFBR is free of, or substantially free of, an active agent (e.g. nicotine).

[0128] In a second aspect the present disclosure provides an aerosol-generating system comprising the aerosol-generating article according to the first aspect, and an aerosol-generating unit. In some examples, the aerosol-generating unit comprises a heater.

[0129] The aerosol-generating system is a system comprising an aerosol-generating article as described herein for the first aspect, and an aerosol-generating apparatus. The aerosol-generating apparatus is an HT device. The aerosol-generating apparatus comprises a heater for heating the aerosol-generating article, in use. The aerosol-generating article is an HT consumable. The aerosol-generating apparatus may be specifically adapted to receive an aerosol-generating article as described herein. The arrangement and preparation of such systems are not otherwise limited.

[0130] In a third aspect the present disclosure provides a use of an aerosol-generating article according to the first aspect, or of an aerosol-generating system according to the second aspect, for the generation of an aerosol for inhalation by a user.

[0131] In some examples, the use of the aerosol-generating system results in the generation of an aerosol for consumption by a user. The use may involve heating the aerosol-generating article by using (e.g. activating) the aerosol-generating apparatus. In some examples, the aerosol-generating article is positioned in proximity or in contact with the heater of the aerosol-generating apparatus. In some examples, the apparatus is actuated to initiate heating of the article. Upon heating, an aerosol may be generated from the aerosol-generating segment, e.g. by volatising an active agent (e.g. nicotine) and / or aerosol formers (e.g. PG and / or VG). The generated aerosol may pass along the flowpath of the article. In some examples, the aerosol moves downstream, through the AFBR, to a mouthpiece at a downstream end.

[0132] In a fourth aspect the present disclosure provides a method of preparing an aerosol-generating segment for use in an aerosol generating article. The method comprises the steps of:

[0133] (i) providing a rod comprising an aerosol-generating material, the rod having an axial length, and the aerosol-generating material comprising an aerosol-former;

[0134] (ii) applying to at least an axial end portion of the rod an anti-aerosol-former coating; and optionally

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[0136] 20

[0137] (iii) cutting the rod into cut segments, such that a cut segment has one or two cut axial ends; and

[0138] (iv) applying to at least one cut axial end an anti-aerosol-former coating.

[0139] The method of the fourth aspect can be used to prepare an article according to the first aspect, optionally for use in the third aspect.

[0140] The anti-aerosol-former coating applied in the method of the fourth aspect may, in some examples, correspond to the aerosol former buffer region described herein. In addition, the anti-aerosol-former coating may be applied more widely than the axial end, so that it may also prevent, minimise or reduce migration of aerosol former from between the seams of a wrapper described in the first aspect.

[0141] In some examples, the method comprises providing a rod comprising an aerosol-generating material, wherein the rod has an axial length, and the aerosol-generating material comprises an aerosol-former. In some examples, the method further comprises applying to at least an axial end portion of the rod an anti-aerosol-former coating. Hence, the method may comprise preparing a rod of aerosol-generating material comprising an anti-aerosol-former coating on at least one axial end portion.

[0142] The rod has an axial length. In some examples, the rod is cylindrical or prismatic in shape, and in some examples the rod comprises a generally constant cross-section normal to its longitudinal axis. In some examples, the rod is cylindrical. In some examples, the rod has a generally circular cross-section. In some examples, the rod is cuboidal (i.e. having a square or rectangular cross-section). In some examples, the rod has an oval cross-section. In some examples, the cut segment is similarly cylindrical or prismatic in shape, the shape differing from that of the rod only in its longitudinal length.

[0143] Thus, also disclosed herein is a method of preparing a rod of aerosol-generating material, the method comprising the steps of:

[0144] (i) providing a rod comprising an aerosol-generating material, the rod having an axial length, and the aerosol-generating material comprising an aerosol-former; and

[0145] (ii) applying to at least an axial end portion of the rod an anti-aerosol-former coating.

[0146] In some examples, the coating is applied to both axial end portions of the rod.

[0147] By preparing a rod of aerosol-generating material comprising an anti-aerosol-former coating on at least one axial end portion, the rod of aerosol-generating material may be stored and / or transported without aerosol-former leaching out of the end portions. This may maintain an optimum amount of aerosolformer in the aerosol-generating material and / or may prevent the surrounding environment or packaging becoming saturated or partially saturated with aerosol-former. The rod may then subsequently be used to prepare aerosol-generating segments for use in aerosol-generating articles, such as articles of the first aspect.

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[0149] 21

[0150] In some examples, the method comprises cutting the rod into cut segments, such that a cut segment has one or two cut axial ends. In some examples, the method further comprises applying to at least one cut axial end an anti-aerosol-former coating, thus forming an aerosol-generating segment comprising an anti-aerosol-former coating on at least one cut axial end. In some examples, the cut segment comprises two cut axial ends. In some examples, the coating is applied to both cut axial ends.

[0151] By preparing an aerosol-generating segment comprising an anti-aerosol-former coating on at least one cut axial end, migration of aerosol-former out of the aerosol-generating segment, when included in an aerosol-generating segment, into neighbouring segments or out of an end of the article can be mitigated or prevented. This may reduce or prevent discoloration of the product due to seepage of aerosol-former into the neighbouring segments or the wrapper (e.g. combining paper). This may have the effect of improving the visual appeal, improving the user experience, and / or increasing the shelf life of the product. The inclusion of an anti-aerosol-former coating may additionally or alternatively reduce the likelihood of breakage of the article by reducing or preventing the neighbouring segments or the wrapper (e.g. combining paper) from becoming saturated, partially saturated, or “damp” with the aerosol-former. This may have the effect of increasing the shelf life of the product, increasing the strength of the product, and improving the user experience by reducing the likelihood of a “damp” feeling.

[0152] The anti-aerosol former coating may prevent or mitigate (e.g. reduce or minimise) movement of the aerosol-former across the coating. In other words, the anti-aerosol-former coating may act as a barrier for aerosol-former. In some examples, the anti-aerosol-former coating helps keep the aerosol-former within the aerosol-generating material of the rod or aerosol-generating segment.

[0153] In some examples, the anti-aerosol-former coating does not prevent movement of an aerosol generated from the aerosol-generating material. That is, the coating may act as a barrier to the movement of aerosol-former before it is vaporised. In some examples, the coating acts as an aerosol-former barrier prior to use of an aerosol-generating article comprising an aerosol-generating segment prepared according to the method described herein. In some examples, the coating prevents or mitigates migration of a liquid or solvated (e.g. aqueous) aerosol-former.

[0154] The anti-aerosol-former coating is a coating comprising an anti-aerosol-former material. In some examples, the coating is an anti-humectant coating, such as a hydrophobic coating, i.e. the anti-aerosol- former material comprises an anti-humectant material, such as a hydrophobic material. In some examples, the coating is an anti-humectant coating, i.e. the anti-aerosol-former material comprises an anti-humectant material. In some examples, the coating comprises silica, particularly hydrophobic silica, e.g. the anti-aerosol-former material comprises silica such as hydrophobic silica. In some examples, the coating comprises a wax, e.g. the anti-aerosol-former material comprises a wax, such as beeswax or carnauba wax. In some examples, the anti-aerosol-former material comprises an oil. In some examples, the anti-aerosol-former coating or material comprises an alginate (e.g. sodium alginate, potassium alginate, or calcium alginate). In some examples, the anti-aerosol-former coating or material

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[0156] 22 comprises gelatine. In some examples, the anti-aerosol-former coating or material is polymeric. In some examples, the anti-aerosol-former coating or material is a plastic. In some examples, the coating is a vapour-selective membrane (i.e. a membrane which is permeable to vapour but not liquid).

[0157] In some examples, the coating has a thickness of between 500 nm and 500 pm. In some examples, the thickness may be 500 nm or more, 750 nm or more, 1 pm or more, 2.5 pm or more, 5 pm or more, 7.5 pm or more, 10 pm or more, 15 pm or more, 20 pm or more, 25 pm or more, 30 pm or more, 40 pm or more, 50 pm or more, 75 pm or more, 100 pm or more, 150 pm or more, 200 pm or more, 250 pm or more, 300 pm or more, or 400 pm or more. In some examples, the thickness may be 500 pm or less, 450 pm or less, 400 pm or less, 350 pm or less, 300 pm or less, 250 pm or less, 200 pm or less, 150 pm or less, 100 pm or less, 75 pm or less, 50 pm or less, 40 pm or less, 30 pm or less, 25 pm or less, 20 pm or less, 15 pm or less, 10 pm or less, 7.5 pm or less, 5 pm or less, 2.5 pm or less, 1 pm or less, or 750 nm or less. Any of the foregoing may be combined to form a suitable range, such as between 500 nm and 250 pm, between 10pm and 75 pm, or between 200 pm and 400 pm.

[0158] In some examples, the cut segments have two cut axial ends (e.g. in step (iii)). The cut segment may have one cut axial end when it is cut from an axial end portion of the rod. The cut segment may have two cut axial ends when it is cut from a middle portion (i.e. non-axial end portion) of the rod. In some examples when the cut segment comprises two cut axial ends, the coating is applied to both cut ends (e.g. in step (iv)). Hence, also described is a method of preparing an aerosol-generating segment comprising an anti-aerosol-former coating on at least one axial end, for example on one axial end or on two axial ends.

[0159] In some examples, the method further comprises applying an anti-aerosol-former coating to a circumferential surface of the rod or the cut segment. The circumferential surface includes all longitudinal faces on the cylindrical or prismatic shape of the rod or cut segment, i.e. the faces circumscribing the longitudinal axis. In some examples, the anti-aerosol-former coating is applied to the entire circumferential surface. In some examples, the anti-aerosol-former coating is applied to a portion of the circumferential surface. In some examples, the anti-aerosol-former coating is applied to the entire outer surface of the rod or cut segment.

[0160] In some examples, the coating is applied to the circumferential surface of the rod before it is applied to one or both axial end portions (i.e. prior to step (ii)). In some examples, the coating is applied to the circumferential surface and to one or both axial end portions of the rod substantially simultaneously (i.e. during step (ii)). In some examples, the coating is applied to the circumferential surface of the rod after it is applied to one or both axial end portions (i.e. after step (ii)). In some examples, the coating is applied to the circumferential surface of the rod before the rod is cut (i.e. prior to step (iii)).

[0161] In some examples, the coating is applied to the circumferential surface of the cut segment after the rod has been cut (i.e. after step (iii)). In some examples, the coating is applied to the circumferential surface

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[0163] 23 and to one or both cut axial ends of the cut segment substantially simultaneously (i.e. during step (iv)). In some examples, the coating is applied to the circumferential surface of the cut segment before it is applied to one or both cut axial ends (i.e. before step (iv)). In some examples, the coating is applied to the circumferential surface of the cut segment after it is applied to one or both cut axial ends (i.e. after step (iv)).

[0164] The coating may be applied by any method known to those in the art. In some examples, the coating is applied by spraying a coating material directly onto the rod or the cut segment. In some examples, the coating material may be applied directly onto the rod or cut segment, for example using a nozzle, a dispenser, a brush, or an applicator. In some examples, the coating material is applied by dipping or submerging all or part of the rod or cut segment into a reservoir of the coating material.

[0165] In some examples, the coating material is a liquid or aerosol which may be sprayed onto the rod or cut segment. In some examples, the coating material is a liquid which forms a coating when allowed to dry on a surface. In some examples, the coating material is particulate which forms a particulate layer on a surface which acts as a coating. In some examples, the coating material is an aerosol which deposits on a surface to form a coating.

[0166] In a fifth aspect, the present disclosure provides a method of preparing an aerosol-generating article for use in an aerosol-generating system. The method comprises preparing an aerosol-generating segment according to the method of the fourth aspect, and preparing an aerosol-generating article comprising said segment.

[0167] For example, an aerosol-generating article may be prepared by wrapping an aerosol-generating segment prepared according to the first aspect with a combining paper. One or more other segments may be wrapped simultaneously with the combining paper. In some examples, the one or more other segments include one or more selected from a mouthpiece, a filter (e.g. a monoacetate filter), a cooling segment, a hollow bore filter, a flavour capsule, and a further aerosol-generating segment. In some examples, the aerosol-generating segment is positioned at an axial end portion of the aerosolgenerating article.

[0168] For example, the method comprises steps (i)-(iv) of the first aspect, and further comprises the step of wrapping the aerosol-generating segment (i.e. the cut segment comprising one or more axial ends comprising a coating) and one or more additional segments with a combining paper.

[0169] The preceding summary is provided for purposes of summarizing some examples to provide a basic understanding of aspects of the subject matter described herein. Accordingly, the above-described features should not be construed to narrow the scope or spirit of the subject matter described herein in any way. Moreover, the above and / or proceeding examples may be combined in any suitable

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[0171] 24 combination to provide further examples, except where such a combination is clearly impermissible or expressly avoided. Other features, aspects, and advantages of the subject matter described herein will become apparent from the following text and the accompanying drawings.

[0172] BRIEF DESCRIPTION OF THE FIGURES

[0173] Aspects, features and advantages of the present disclosure will become apparent from the following description of examples in reference to the appended drawings in which like numerals denote like elements.

[0174] Fig. 1 is a block system diagram showing an example aerosol generating apparatus.

[0175] Fig. 2 is a block system diagram showing an example implementation of the apparatus of Fig. 1 , where the aerosol generating apparatus is configured to generate aerosol from a solid precursor.

[0176] Fig. 3 is a schematic diagram showing an example implementation of the apparatus of Fig. 2.

[0177] Fig. 4 is a schematic diagram showing a cross-section through an example implementation of the aerosol-generating article.

[0178] Fig. 5 is a schematic diagram showing a cross-section through an example implementation of the aerosol-generating article.

[0179] Fig. 6 is a schematic diagram showing a cross-section through an example implementation of the aerosol-generating article.

[0180] Fig. 7 is a schematic diagram showing a cross-section through an example implementation of the aerosol-generating article.

[0181] Fig. 8 is a schematic diagram showing a cross-section through an example implementation of the aerosol-generating article.

[0182] Fig. 9 is a schematic diagram showing a cross-section through an example implementation of the aerosol-generating article.

[0183] Fig. 10 is a schematic diagram showing a cross-section through an example implementation of the aerosol-generating article.

[0184] Fig. 11 is a schematic diagram showing a cross-section through an example implementation of the aerosol-generating article.

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[0187] DETAILED DESCRIPTION OF EMBODIMENTS

[0188] Before describing several examples implementing the present disclosure, it is to be understood that the present disclosure is not limited by specific construction details or process steps set forth in the following description and accompanying drawings. Rather, it will be apparent to those skilled in the art having the benefit of the present disclosure that the systems, apparatuses and / or methods described herein could be embodied differently and / or be practiced or carried out in various alternative ways.

[0189] Unless otherwise defined herein, scientific and technical terms used in connection with the presently disclosed inventive concept(s) shall have the meanings that are commonly understood by those of ordinary skill in the art and known techniques and procedures may be performed according to conventional methods well known in the art and as described in various general and more specific references that may be cited and discussed in the present specification.

[0190] Any patents, published patent applications, and non-patent publications mentioned in the specification are hereby incorporated by reference in their entirety.

[0191] All examples implementing the present disclosure can be made and executed without undue experimentation in light of the present disclosure. While particular examples have been described, it will be apparent to those of skill in the art that variations may be applied to the systems, apparatus, and / or methods and in the steps or in the sequence of steps of the methods described herein without departing from the concept, spirit, and scope of the inventive concept(s). All such similar substitutions and modifications apparent to those skilled in the art are deemed to be within the spirit, scope, and concept of the inventive concept(s) as defined by the appended claims.

[0192] The use of the term “a” or “an” in the claims and / or the specification may mean “one,” as well as “one or more,” “at least one,” and “one or more than one.” As such, the terms “a,” “an,” and “the,” as well as all singular terms, include plural referents unless the context clearly indicates otherwise. Likewise, plural terms shall include the singular unless otherwise required by context.

[0193] The use of the term “or” in the present disclosure (including the claims) is used to mean an inclusive “and / or” unless explicitly indicated to refer to alternatives only or unless the alternatives are mutually exclusive. In some examples, a condition “A or B” is satisfied by any of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).

[0194] As used in this specification and claim(s), the words “comprising, “having,” “including,” or “containing” (and any forms thereof, such as “comprise” and “comprises,” “have” and “has,” “includes” and “include,” or “contains” and “contain,” respectively) are inclusive or open-ended and do not exclude additional, unrecited elements or method steps.

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[0197] Unless otherwise explicitly stated as incompatible, or the physics or otherwise of the embodiments, examples, or claims prevent such a combination, the features of examples disclosed herein, and of the claims, may be integrated together in any suitable arrangement, especially ones where there is a beneficial effect in doing so. This is not limited to only any specified benefit, and instead may arise from an “ex post facto” benefit. This is to say that the combination of features is not limited by the described forms, particularly the form (e.g. numbering) of example(s), embodiment(s), or dependency of claim(s). Moreover, this also applies to the phrase “in one embodiment,” “according to an embodiment,” and the like, which are merely a stylistic form of wording and are not to be construed as limiting the following features to a separate embodiment to all other instances of the same or similar wording. This is to say, a reference to ‘an,’ ‘one,’ or ‘some’ embodiment(s) may be a reference to any one or more, and / or all embodiments, or combination(s) thereof, disclosed. Also, similarly, the reference to “the” embodiment may not be limited to the immediately preceding embodiment. Further, all references to one or more embodiments or examples are to be construed as non-limiting to the claims.

[0198] The present disclosure may be better understood in view of the following explanations, wherein the terms used that are separated by “or” may be used interchangeably:

[0199] As used herein, an "aerosol generating apparatus" (or “electronic(e)-cigarette ’) may be an apparatus configured to deliver an aerosol to a user for inhalation by the user. The apparatus may additionally / alternatively be referred to as a “smoking substitute apparatus”, if it is intended to be used instead of a conventional combustible smoking article. As used herein a combustible “smoking article” may refer to a cigarette, cigar, pipe or other article, that produces smoke (an aerosol comprising solid particulates and gas) via heating above the thermal decomposition temperature (typically by combustion and / or pyrolysis). An aerosol generated by the apparatus may comprise an aerosol with particle sizes of 0.2 - 7 microns, or less than 10 microns, or less than 7 microns. This particle size may be achieved by control of one or more of: heater temperature; cooling rate as the vapour condenses to an aerosol; flow properties including turbulence and velocity. The generation of aerosol by the aerosol generating apparatus may be controlled by an input device. The input device may be configured to be user-activated and may for example include or take the form of an actuator (e.g. actuation button) and / or an airflow sensor.

[0200] Each occurrence of the aerosol generating apparatus being caused to generate aerosol for a period of time (which may be variable) may be referred to as an “activation” of the aerosol generating apparatus. The aerosol generating apparatus may be arranged to allow an amount of aerosol delivered to a user to be varied per activation (as opposed to delivering a fixed dose of aerosol), e.g. by activating an aerosol generating unit of the apparatus for a variable amount of time, e.g. based on the strength / duration of a draw of a user through a flow path of the apparatus (to replicate an effect of smoking a conventional combustible smoking article).

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[0202] 27

[0203] The aerosol generating apparatus may be portable. As used herein, the term "portable" may refer to the apparatus being for use when held by a user.

[0204] As used herein, an "aerosol generating system" may be a system that includes an aerosol generating apparatus and optionally other circuitry / components associated with the function of the apparatus, e.g. one or more external devices and / or one or more external components (here “external” is intended to mean external to the aerosol generating apparatus). As used herein, an “external device” and “external component” may include one or more of a: a charging device, a mobile device (which may be connected to the aerosol generating apparatus, e.g. via a wireless or wired connection); a networked-based computer (e.g. a remote server); a cloud-based computer; any other server system.

[0205] An example aerosol generating system may be a system for managing an aerosol generating apparatus. Such a system may include, for example, a mobile device, a network server, as well as the aerosol generating apparatus.

[0206] As used herein, an "aerosol" may include a suspension of precursor, including as one or more of: solid particles; liquid droplets; gas. Said suspension may be in a gas including air. An aerosol herein may generally refer to / include a vapour. An aerosol may include one or more components of the precursor.

[0207] As used herein, a “precursor” may include one or more of a: liquid; solid; gel; loose leaf material; other substance. The precursor may be processed by an aerosol generating unit of an aerosol generating apparatus to generate an aerosol. The precursor may include one or more of: an active component; a carrier; a flavouring. The active component may include one or more of nicotine; caffeine; a cannabidiol oil; a non-pharmaceutical formulation, e.g. a formulation which is not for treatment of a disease or physiological malfunction of the human body. The active component may be carried by the carrier, which may be a liquid, including propylene glycol and / or glycerine. The term “flavouring” may refer to a component that provides a taste and / or a smell to the user. The flavouring may include one or more of: Ethylvanillin (vanilla); menthol, Isoamyl acetate (banana oil); or other. The precursor may include a substrate, e.g. reconstituted tobacco to carry one or more of the active component; a carrier; a flavouring.

[0208] As used herein, a “substrate” may refer to a solid precursor (e.g. loose-leaf precursor material or a “stick” of precursor material such as tobacco), or an absorbent material (e.g. fibrous non-precursor material, such as cotton or hemp) that is imbued with a precursor (e.g. liquid or gel precursor). A substrate may also be referred to as an “aerosol-generating substrate”.

[0209] As used herein, a "storage portion" may be a portion of the apparatus adapted to store the precursor. It may be implemented as fluid-holding reservoir or carrier for solid material depending on the implementation of the precursor as defined above.

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[0211] 28

[0212] As used herein, a "flow path" may refer to a path or enclosed passageway through an aerosol generating apparatus, e.g. for delivery of an aerosol to a user. The flow path may be arranged to receive aerosol from an aerosol generating unit. When referring to the flow path, upstream and downstream may be defined in respect of a direction of flow in the flow path, e.g. with an outlet being downstream of an inlet.

[0213] As used herein, a "delivery system" may be a system operative to deliver an aerosol to a user. The delivery system may include a mouthpiece and a flow path.

[0214] As used herein, a "flow" may refer to a flow in a flow path. A flow may include aerosol generated from the precursor. The flow may include air, which may be induced into the flow path via a puff by a user.

[0215] As used herein, a “puff” (or "inhale" or “draw”) by a user may refer to expansion of lungs and / or oral cavity of a user to create a pressure reduction that induces flow through the flow path.

[0216] As used herein, an "aerosol generating unit" may refer to a device configured to generate an aerosol from a precursor. The aerosol generating unit may include a unit to generate a vapour directly from the precursor (e.g. a heating system or other system) or an aerosol directly from the precursor (e.g. an atomiser including an ultrasonic system, a flow expansion system operative to carry droplets of the precursor in the flow without using electrical energy or other system). A plurality of aerosol generating units to generate a plurality of aerosols (for example, from a plurality of different aerosol precursors) may be present in an aerosol generating apparatus.

[0217] As used herein, a “heating system” may refer to an arrangement of at least one heating element, which is operable to aerosolise a precursor once heated. The at least one heating element may be electrically resistive to produce heat from the flow of electrical current therethrough. The at least one heating element may be arranged as a susceptor to produce heat when penetrated by an alternating magnetic field. The heating system may be configured to heat a precursor to below 300 or 350 degrees C, including without combustion.

[0218] As used herein, a "consumable" may refer to a unit that includes a precursor. The consumable may include an aerosol generating unit, e.g. it may be arranged as a cartomizer. The consumable may include a mouthpiece. The consumable may include an information carrying medium. With liquid or gel implementations of the precursor, e.g. an e-liquid, the consumable may be referred to as a “capsule” or a “pod” or an “e-liquid consumable”. The capsule / pod may include a storage portion, e.g. a reservoir or tank, for storage of the precursor. With solid material implementations of the precursor, e.g. tobacco or reconstituted tobacco formulation, the consumable may be referred to as a “stick” or “package” or “heat- not-burn consumable”. In a heat-not-burn consumable, the mouthpiece may be implemented as a filter and the consumable may be arranged to carry the precursor. The consumable may be implemented as a dosage or pre-portioned amount of material, including a loose-leaf product.

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[0220] 29

[0221] As used herein, an "information carrying medium" may include one or more arrangements for storage of information on any suitable medium. Examples include: a computer readable medium; a Radio Frequency Identification (RFID) transponder; codes encoding information, such as optical (e.g. a bar code or QR code) or mechanically read codes (e.g. a configuration of the absence or presents of cutouts to encode a bit, through which pins or a reader may be inserted).

[0222] As used herein “heat-not-burn” (or “HNB” or “heated precursor”) may refer to the heating of a precursor, typically tobacco, without combustion, or without substantial combustion (i.e. localised combustion may be experienced of limited portions of the precursor, including of less than 5% of the total volume).

[0223] Referring to Fig. 1 , an example aerosol generating apparatus 1 includes a power supply 2, for supply of electrical energy. The apparatus 1 includes an aerosol generating unit 4 that is driven by the power supply 2. The power supply 2 may include an electric power supply in the form of a battery and / or an electrical connection to an external power source. The apparatus 1 includes a precursor (aerosolgenerating segment) 6, which in use is aerosolised by the aerosol generating unit 4 to generate an aerosol. The apparatus 2 includes a delivery system 8 for delivery of the aerosol to a user.

[0224] Electrical circuitry (not shown in figure 1) may be implemented to control the interoperability of the power supply 4 and aerosol generating unit 6.

[0225] Fig. 2 shows an implementation of the apparatus 1 of Fig. 1 , where the aerosol generating apparatus 1 is configured to generate aerosol by a-heat not-burn process.

[0226] In this example, the apparatus 1 includes a device body 50 and a consumable (aerosol-generating article) 70.

[0227] In this example, the body 50 includes the power supply 4 and a heating system 52. The heating system 54 includes at least one heating element 54. The body may additionally include any one or more of electrical circuitry 56, a memory 58, a wireless interface 60, one or more other components 62.

[0228] The electrical circuitry 56 may include a processing resource for controlling one or more operations of the body 50, e.g. based on instructions stored in the memory 58.

[0229] The wireless interface 60 may be configured to communicate wirelessly with an external (e.g. mobile) device, e.g. via Bluetooth.

[0230] The other component(s) 62 may include an actuator, one or more user interface devices configured to convey information to a user and / or a charging port, for example (see e.g. Fig. 3).

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[0232] 30

[0233] The body 50 is configured to engage with the consumable 70 such that the at least one heating element 54 of the heating system 52 penetrates into the solid precursor 6 of the consumable. In use, a user may activate the aerosol generating apparatus 1 to cause the heating system 52 of the body 50 to cause the at least one heating element 54 to heat the solid precursor 6 of the consumable (without combusting it) by conductive heat transfer, to generate an aerosol which is inhaled by the user.

[0234] Fig. 3 shows an example implementation of the aerosol generating device 1 of Fig. 2.

[0235] As depicted in Fig. 3, the consumable 70 is implemented as a stick, which is engaged with the body 50 by inserting the stick into an aperture at a top end 53 of the body 50, which causes the at least one heating element 54 of the heating system 52 to penetrate into the solid precursor 6.

[0236] The consumable 70 includes the solid precursor 6 proximal to the body 50, and a filter distal to the body 50. The filter serves as the mouthpiece of the consumable 70 and thus the apparatus 1 as a whole. The solid precursor 6 may be a reconstituted tobacco formulation.

[0237] In this example, the at least one heating element 54 is a rod-shaped element with a circular transverse profile. Other heating element shapes are possible, e.g. the at least one heating element may be bladeshaped (with a rectangular transverse profile) or tube-shaped (e.g. with a hollow transverse profile).

[0238] In this example, the body 50 includes a cap 51. In use the cap 51 is engaged at a top end 53 of the body 50. Although not apparent from Fig. 3, the cap 51 is moveable relative to the body 50. In particular, the cap 51 is slidable and can slide along a longitudinal axis of the body 50.

[0239] The body 50 also includes an actuator 55 on an outer surface of the body 50. In this example, the actuator 55 has the form of a button.

[0240] The body 50 also includes a user interface device configured to convey information to a user. Here, the user interface device is implemented as a plurality of lights 57, which may e.g. be configured to illuminate when the apparatus 1 is activated and / or to indicate a charging state of the power supply 4.

[0241] Other user interface devices are possible, e.g. to convey information haptically or audibly to a user.

[0242] The body may also include an airflow sensor which detects airflow in the aerosol generating apparatus 1 (e.g. caused by a user inhaling through the consumable 70). This may be used to count puffs, for example.

[0243] In this example, the consumable 70 includes a flow path which transmits aerosol generated by the at least one heating element 54 to the mouthpiece of the consumable.

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[0245] 31

[0246] In this example, the aerosol generating unit 4 is provided by the above-described heating system 52 and the delivery system 8 is provided by the above-described flow path and mouthpiece of the consumable 70.

[0247] One exemplary embodiment of an aerosol-generating article 72 is shown schematically in longitudinal cross-section in Fig. 4. The aerosol-generating article 72 is generally cylindrical in geometry and has a width (perpendicular to its longitudinal axis) of 7.2 mm. The aerosol-generating article 72 includes an aerosol-generating segment 41 of length 12 mm which is formed from slit and gathered cast leaf tobacco. Moving in a downstream direction, the aerosol-generating article 72 then includes an aerosol former buffer region (AFBR) 46 in the form of a void of length of 2-5 mm immediately downstream of the aerosol-generating substrate 41. The AFBR 46 abuts the aerosol-generating segment 41 across the whole axial cross-section. The void separates the aerosol-generating segment 41 from a second segment, the second segment being a monoacetate filter 42 of length 7 mm which lies downstream. The void 46 thereby acts as a gap between the aerosol-generating segment 41 and the filter 42. Although a filter 42 is depicted as the second segment, it will be understood that other components may act as a second segment in place of the filter 42.

[0248] Immediately downstream of the filter 42 lies a cooling segment 43 in the form of a cardboard tube of length 14 mm. Finally, a mouthpiece filter 44 of length 12 mm made of monoacetate lies at the terminal downstream end of the aerosol-generating article 72, immediately downstream of the cooling segment 43. The mouthpiece filter 44 is shown in Fig. 4 as a hollow bore filter, but in other examples a solid filter may be used instead. The filter 42 and cardboard tube 43 abut one another, and the cardboard tube 43 and mouthpiece filter 44 also abut one another. The entire assembly of aerosol-generating substrate 41 , AFBR 46, filter 42, cooling segment 43 and mouthpiece filter 44 are circumscribed by (bounded by) a paper wrapper (not shown in Fig. 4) and the mouthpiece filter 44 and part of the cardboard tube 43 are circumscribed by tipping paper (also not shown in Fig. 4) which overlies the paper wrapper. Between the paper wrapper and the aerosol-generating substrate 41 lies an aluminium-lined paper wrapper (not shown) which may circumscribe only the aerosol-generating segment 41 , or the aerosolgenerating segment 41 and the AFBR 46, with the aluminium layer facing inwards. The direction of aerosol flow through the aerosol-generating article is shown by an arrow 45.

[0249] When the aerosol-generating segment is not being heated by an aerosol-generating apparatus / device, aerosol former is present in the aerosol-generating segment 41 and its movement into the filter 42 is mitigated or prevented by the presence of the AFBR 46. That is, the liquid aerosol former does not easily migrate through the AFBR 46. The same effect would be demonstrated if another type of second segment were present instead of or in addition to the filter 42, and if another type of AFBR 42 was used instead of a void.

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[0251] 32

[0252] During use, the aerosol-generating article 72 is inserted into an aerosol-generating device such as the aerosol generating device 1 of Fig. 3. When the heater is activated by the user, the aerosol-generating substrate 41 is heated until components of the aerosol-generating substrate 41 are volatilised and form an aerosol. As the user draws on the mouthpiece filter 44, the aerosol stream is drawn through the aerosol-generating article 72 in the direction of arrow 45, from the aerosol-generating segment 41 and through the AFBR 46 (which lies immediately downstream) toward, and eventually exiting through, the mouthpiece 44.

[0253] Fig. 5 shows another exemplary embodiment of an aerosol-generating article 73 shown schematically in longitudinal cross-section. The aerosol-generating article 73 is very similar to aerosol-generating article 72 in Fig. 4, so common structure will not be described again in detail. In aerosol-generating article 73, the second segment is depicted as a hollow bore filter 42’. Those skilled in the art will understand that any suitable second segment may be included, and various types of, e.g., filters are available for such a segment. The hollow bore filter 42’ comprises a channel (i.e. a bore) of diameter 3.5 mm through its longitudinal axis to improve flow of aerosol when drawn by a user. The hollow bore filter 42’ is separated from the aerosol-generating segment 41 by the AFBR 46 in the form of a void (or gap).

[0254] Fig. 6 shows another exemplary embodiment of an aerosol-generating article 74 shown schematically in longitudinal cross-section. The aerosol-generating article 74 is very similar to aerosol-generating article 72 in Fig. 4, so common structure will not be described again in detail. The AFBR 46 is a void comprising a tube 47. The tube 47 is made of card and provides structure to the void. The tube 47 has a diameter equal to the diameter of the aerosol-generating segment 41. The tube 47 maintains the distance between the aerosol-generating segment 41 and the second segment 42, both of which it abuts. Although not depicted in Fig. 6, the tube 47 comprises a foil lining or a coating on its inner surface to prevent seepage of aerosol former into the wrapper of the article (wrapper not shown in Fig. 6).

[0255] Fig. 7 shows another exemplary embodiment of an aerosol-generating article 75 shown schematically in longitudinal cross-section. The aerosol-generating article 75 is very similar to aerosol-generating article 72 in Fig. 4, so common structure will not be described again in detail. The AFBR 46 is a void further comprising a paper rod 48 which acts as a spacer. The spacer is made from a rolled piece of paper, the piece of paper having a width equal to the length of the AFBR 46. The paper rod 48 has a diameter of 2.75 mm. The rod 48 has a diameter substantially less than the diameter of the aerosolgenerating segment 41. The rod 48 maintains the distance between the aerosol-generating segment 41 and the filter 42, both of which it abuts.

[0256] Fig. 8 shows another exemplary embodiment of an aerosol-generating article 76 shown schematically in longitudinal cross-section. The aerosol-generating article 76 is very similar to aerosol-generating article 72 in Fig. 4, so common structure will not be described again in detail. The AFBR 46 is a solid substrate, which acts as “sacrificial segment”. The AFBR 46 may have a length in the longitudinal axis

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[0258] 33 of around 8 mm. During storage (i.e., when the aerosol-generating segment is not being heated by an aerosol-generating apparatus / device), aerosol former is present in the aerosol-generating segment 41 and its movement into the second segment 42 is mitigated or prevented by the presence of the AFBR 46. That is, the liquid aerosol former may migrate into the AFBR 46, but it does not easily pass through the entire length of the AFBR 46 into the second segment 42. Hence, the AFBR 46 is “sacrificial” because it is intended to absorb some of the aerosol former whilst slowing or preventing its movement into further downstream segments. Although not depicted, the AFBR 46 is covered by a foil sheet to prevent aerosol former seeping out of the AFBR 46 into the article wrapper (wrapper not shown).

[0259] Fig. 9 shows another exemplary embodiment of an aerosol-generating article 77 shown schematically in longitudinal cross-section. The aerosol-generating article 77 is very similar to aerosol-generating article 76 in Fig. 8, so common structure will not be described again in detail. The AFBR 46 is a “sacrificial segment” as in aerosol-generating article 76. The AFBR 46 may have a length in the longitudinal axis of around 15 mm. In aerosol-generating article 77, there is no filter shown as the second segment, instead the AFBR 46 is immediately upstream of the cooling segment 43. That is, the cooling segment 43 and the aerosol-generating segment 41 are separated only by the AFBR 46. That is, the cooling segment 43 acts as the second segment described herein.

[0260] Fig. 10 shows another exemplary embodiment of an aerosol-generating article 78 shown schematically in longitudinal cross-section. The aerosol-generating article 78 is very similar to aerosol-generating article 72 in Fig. 4, so common structure will not be described again in detail. The aerosol-generating article 78 has an AFBR 46, as described in aerosol-generating article 72. However, aerosol-generating article 78 also has a second AFBR 46’, located upstream of and abutting the aerosol-generating segment 41 . The second AFBR 46’ is a void bounded by the wrapper. The second AFBR 46’ may have a length in the longitudinal axis of around 3 mm. The second AFBR 46’ is a terminal segment at the upstream end of the article. In effect, the aerosol-generating segment 41 is inset from the upstream end of the article. Although both the AFBR 46 and the second AFBR 46’ are depicted as a void in Fig. 10, it will be understood that either could be replaced with any other AFBR as described herein. In some examples, one may be a void and the other may be a sacrificial segment, they may both be a sacrificial segment, and / or the void(s) may contain a spacer(s) and / or coating(s) as described herein.

[0261] Fig. 1 1 shows another exemplary embodiment of an aerosol-generating article 79 shown schematically in longitudinal cross-section. The aerosol-generating article 79 is very similar to aerosol-generating article 72 in Fig. 4, so common structure will not be described again in detail. The aerosol-generating article 79 has an AFBR 46, as in aerosol-generating article 72. However, aerosol-generating article 79 also has a second AFBR 46’, located further downstream of and abutting the AFBR 46. That is, aerosolgenerating article 79 comprises two sequential and abutting AFBRs. That is, the aerosol-generating segment 41 and the second segment 42 are separated by the AFBR 46 and the second AFBR 46’. The AFBR 46 is a void, as in aerosol-generating article 72, and the second AFBR 46’ is a sacrificial segment, as in aerosol-generating article 76 (though not necessarily of the same length as in aerosol-generating

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[0263] 34 article 76). The second AFBR 46’ may have a length in the longitudinal axis of around 3 mm. Although the first AFBR 46 is depicted as a void and the second AFBR 46’ is depicted as a sacrificial segment, those in the art will understand that these can be rearranged, for example so that the first AFBR 46 is a sacrificial segment and the second AFBR 46’ is a void. It will also be understood that either could be replaced with any other AFBR as described herein. In some examples, one may be a void and the other may be a sacrificial segment, they may both be a sacrificial segment, and / or the void(s) may contain a spacer(s) and / or coating(s) as described herein.

[0264] 008519555

Claims

P0158735CLAIMS1 . An aerosol-generating article for use in an aerosol-generating system, the aerosol-generating article comprising: an aerosol-generating segment comprising aerosol former, the aerosol-generating segment having a longitudinal direction aligned with a flowpath of the article; and an aerosol former buffer region abutting the aerosol-generating segment at a first end of the aerosol-generating segment in the longitudinal direction; wherein: the aerosol former buffer region has a length aligned with the flowpath of the article of between 0.5 and 20 mm; and the aerosol-generating segment and the aerosol former buffer region are bounded by a connecting wrapper, and wherein either:(i) the aerosol former buffer region comprises a solid substrate comprising an anti-aerosol former material, or(ii) the aerosol former buffer region is a void bounded by the connecting wrapper.

2. The aerosol-generating article according to claim 1 (i), wherein the solid substrate of the aerosol former buffer region comprises aerosol former in an amount less than the amount of aerosol former in the aerosol-generating segment.

3. The aerosol-generating article according to claim 1 (ii), wherein the inner surface of the wrapper bounding the void comprises a coating or lining.

4. The aerosol-generating article according to claim 3, wherein the coating or lining comprises a foil or an anti-aerosol former material.

5. The aerosol-generating article according to claim 3 or claim 4, wherein the coating or lining comprises one or more of:(a) an anti-humectant material, optionally comprising gelatine and / or alginate such as sodium alginate, potassium alginate, and calcium alginate;(b) a hydrophobic material or silica;(c) a wax, optionally selected from beeswax and carnauba wax.

6. The aerosol-generating article according to any one of the preceding claims, wherein the aerosol former buffer region is downstream from the aerosol-generating segment.

7. The aerosol-generating article according to any one of the preceding claims, wherein a length of the aerosol former buffer region is between 0.5 and 20 mm.008519555P01587368. The aerosol-generating article according to claim 7, wherein the length of the aerosol former buffer region is between 6 and 12 mm when the aerosol former buffer region comprises the solid substrate, or is between 0.5 and 6 mm when the aerosol former buffer region is the void.

9. The aerosol-generating article according any one of the preceding claims, wherein the first end of the aerosol-generating segment, and optionally a second end opposite the first end, comprises a coating or lining, optionally wherein the coating or lining comprises an anti-aerosol former material.

10. The aerosol-generating article according to claim 9, wherein the coating or lining comprises one or more of:(a) an anti-humectant material, optionally comprising gelatine and / or alginate such as sodium alginate, potassium alginate, and calcium alginate;(b) a hydrophobic material or silica;(c) a wax, optionally selected from beeswax and carnauba wax.11 . The aerosol-generating article according to any one of the preceding claims, wherein the article comprises a second segment positioned axially downstream or upstream of the aerosolgenerating segment along the flowpath of the article, the second segment and the aerosol-generating segment being separated by the aerosol former buffer region.

12. The aerosol-generating article according to claim 11 , wherein when the aerosol former buffer region is a void, the void comprises a spacer configured to maintain a minimum gap between the aerosol-generating segment and the second segment.

13. The aerosol-generating article according to any one of the preceding claims, comprising a second aerosol former buffer region abutting an opposite end of the aerosol-generating segment to the first end, such that one aerosol former buffer region is upstream of the aerosol-generating segment and one aerosol former buffer region is downstream of the aerosol-generating segment.

14. An aerosol-generating system comprising the aerosol-generating article according to any one of the preceding claims and an aerosol-generating unit.

15. Use of an aerosol-generating article according to any one of claims 1 to 13 or of an aerosolgenerating system according to claim 14 for the generation of an aerosol for inhalation by a user.008519555

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