Mouthpiece element for an aerosol-generating article

Abstract

The invention relates to a mouthpiece element for an aerosol-generating article. The present invention further relates to an aerosol-generating article comprising the mouthpiece element. The mouthpiece element for an aerosol-generating article comprises a tipping wrapper enclosing a filter portion, wherein the filter portion has a diameter, a proximal end and a distal end defining a longitudinal axis, wherein the filter portion comprises a filter material, wherein the filter material has a longitudinally arranged slit extending from the proximal end to the distal end in a direction parallel to the longitudinal axis of the filter portion, wherein the slit has a width and a height, each in a direction perpendicular to the longitudinal axis of the filter portion and perpendicular to each other, and wherein the slit is configured to be opened by applying a compressive force in the width direction of the slit.

Description

[0001] New PCT Patent Application December 15, 2025 Philip Morris Products S.A. 46236-PCT

[0002] -1-

[0003] MOUTHPIECE ELEMENT FOR AN AEROSOL-GENERATING ARTICLE

[0004] The present invention relates to a mouthpiece element for an aerosol-generating article. The present invention further relates to an aerosol-generating article comprising the mouthpiece element. The present invention further relates to an aerosol-generating system comprising the aerosol-generating article and an aerosol generating device. The present invention further relates to a method for manufacturing a mouthpiece element for an aerosolgenerating article.

[0005] It is known to provide aerosol-generating articles comprising aerosol-forming substrate. Such aerosol-generating articles may be heated by an aerosol-generating device to a temperature at which one or more components of the aerosol-forming substrate are volatilised without burning the aerosol-forming substrate. The aerosol-generating article may be rod-shaped and comprise a plurality of portions. The aerosol-generating article may comprise a mouthpiece and a substrate portion comprising an aerosol-forming substrate. The mouthpiece may be arranged at a proximal end of the aerosol-generating article. A user may inhale the generated aerosol through the mouthpiece. The substrate portion and the mouthpiece may be wrapped in two partly overlapping layers of wrapping papers. One of the wrapping papers may be a tipping paper wrapping the mouthpiece. The aerosol-generating article may comprise further portions wrapped in the wrapping papers as, for example, a cooling portion arranged between the substrate portion and the filter portion. The mouthpiece may comprise a filter portion. The filter portion may be a plug of cellulose acetate. Such filter portions, when applied to modern devices such as heat-not-burn (HnB) products, having lower operating temperatures, can lead to an undesirably excessive filtering.

[0006] It would be desirable to provide a mouthpiece with improved filtration properties. It would be desirable to provide a mouthpiece with tuneable filtration properties. It would be desirable to provide a mouthpiece with improved airflow properties. It would be desirable to provide a mouthpiece providing an improved user experience. It would be desirable to provide a mouthpiece having an improved flavor delivery. It would be desirable to provide a mouthpiece offering improved sustainability. It would be desirable to provide a mouthpiece with reduced environmental impact. It would be desirable to provide a replacement for cellulose acetate filters.

[0007] According to an embodiment of the invention there is provided a mouthpiece element for an aerosol-generating article. The mouthpiece element may comprise a tipping wrapper, preferably a tipping paper, enclosing a filter portion. The filter portion may be tubular. The filter portion may have a proximal end and a distal end defining a longitudinal axis. The filter portion New PCT Patent Application December 15, 2025 Philip Morris Products S.A. 46236-PCT

[0008] -2- may comprise a filter material and one or more longitudinally arranged hollow airflow passageways extending in a direction parallel to the longitudinal axis of the filter portion. The filter portion may have a cross-sectional pattern formed by the filter material and the one or more longitudinally arranged hollow airflow passageways. The cross-sectional pattern may be non-circular.

[0009] According to an embodiment of the invention there is provided a mouthpiece element for an aerosol-generating article. The mouthpiece element comprises a tipping wrapper, preferably a tipping paper, enclosing a filter portion. The filter portion is tubular. The filter portion has a proximal end and a distal end defining a longitudinal axis, such that the longitudinal axis extends between the proximal end and the distal end. The filter portion comprises a filter material and one or more longitudinally arranged hollow airflow passageways extending in a direction parallel to the longitudinal axis of the filter portion. The filter portion has a cross-sectional pattern formed by the filter material and the one or more longitudinally arranged hollow airflow passageways. The cross-sectional pattern is non-circular.

[0010] A mouthpiece with improved filtration properties may be provided. A mouthpiece with tuneable filtration properties may be provided. A mouthpiece with improved airflow properties may be provided. A mouthpiece with an improved user experience may be provided. A mouthpiece having an improved flavor delivery may be provided. A mouthpiece offering improved sustainability may be provided. A mouthpiece with reduced environmental impact may be provided. A mouthpiece allowing for replacement for cellulose acetate filters may be provided.

[0011] The patterned cross-section may enhance airflow through the mouthpiece element. The patterned cross-section may reduce the filtration of one or both of active substances and humectants. The patterned cross-section may prevent over-filtration.

[0012] The filter portion may be a cylindrical filter portion. The filter portion may be a tubular filter portion.

[0013] As used herein, the “cross-sectional pattern” may be described as the pattern of a cross-section of the filter portion in a direction perpendicular to the longitudinal axis.

[0014] The cross-sectional pattern may be configured such that 60 % or more, preferably 70 % or more of the area of the cross-sectional pattern are formed by the filter material and 40 % or less, preferably 30 % or less of the area of the cross-sectional pattern are formed by the one or more airflow passageways.

[0015] Between 60 % and 95 % of the area of the cross-sectional pattern may be formed by the filter material and between 5 % and 40 % or the area of the cross-sectional pattern may be formed by the one or more airflow passageways. Between 70 % and 95 % of the area of the New PCT Patent Application December 15, 2025 Philip Morris Products S.A. 46236-PCT

[0016] -3- cross-sectional pattern may be formed by the filter material and between 5 % and 30 % or the area of the cross-sectional pattern may be formed by the one or more airflow passageways.

[0017] As used herein, the term “non-circular cross-sectional pattern” refers to a pattern different to a circle or a circular hollow tube. The order of the rotational symmetry of the “noncircular cross-sectional pattern” is not infinite with respect to a longitudinal central axis of the filter portion.

[0018] The non-circular cross-sectional pattern may comprise one or more geometrical shapes selected from circles having two or more perimetral groves, regular or irregular polygons, semi-circles, cog or gear shapes, hole circles of four or more circles, and regular or irregular polygonal stars.

[0019] The non-circular cross-sectional pattern may comprise an N-fold rotational symmetry with N being a natural number of two or more, for example 3, 5, 5, 6, 7, 8, 9, or 10. The non- circular cross-sectional pattern may comprise an N-fold rotational symmetry with respect to a longitudinal central axis of the filter portion with N being a natural number of two or more, for example 3, 5, 5, 6, 7, 8, 9, or 10.

[0020] The cross-sectional pattern may be constant along the longitudinal axis of the filter portion. In other words, the cross-sectional pattern may be constant along the longitudinal axis of the filter portion, such that the pattern does not vary along the entire length of the filter material. The cross-sectional pattern may be constant along the entire length of the filter portion.

[0021] The filter portion may comprise two or more different cross-sectional patterns along the longitudinal axis of the filter portion. The filter portion may comprise two or more different non- circular cross-sectional patterns along the longitudinal axis of the filter portion. The non-circular cross-sectional pattern may vary over the length of the filter portion.

[0022] The filter material in the filter portion may be a monolithic piece. The filter material in the filter portion may be a monolithic piece and the non-circular cross-sectional pattern may vary over the length of the filter portion.

[0023] The filter material may comprise one or more of filaments, fibers, webs, and extrusions. The filter material may be in the form of filaments, fibers, webs, and / or extrusions. The filter material may comprise or may consist of cellulosic material. The filter material may comprise or may consist of one or more cellulose esters. The cellulose ester may be selected from one or more of cellulose acetate, cellulose propionate, cellulose butyrate, cellulose acetate propionate, and cellulose acetate butyrate. Other examples of the cellulose ester include polycaprolactone grafted cellulose acetate, acetyl methyl cellulose, acetyl ethyl cellulose, acetyl propyl cellulose, acetyl hydroxyethyl cellulose, and acetyl hydroxypropyl cellulose. New PCT Patent Application December 15, 2025 Philip Morris Products S.A. 46236-PCT

[0024] -4-

[0025] The filter material may comprise a plasticizer, preferably an ester-based plasticizer. The filter material may comprise the plasticizer in an amount of 8 wt-% or more, preferably in an amount of 15 wt-% or more, more preferably in an amount of 22 wt-% or more.

[0026] Using such high concentration of plasticizer may help to ensure high structural rigidity, especially in designs with patterns that result in a thin regions of the filtering material.

[0027] The ester-based plasticizer may be selected from one or more of aromatic carboxylic acid esters (e.g., di-C1-12 alkyl phthalates such as dimethyl phthalate, diethyl phthalate, dibutyl phthalate, dihexyl phthalate, dioctyl phthalate, and di-2-ethylhexyl phthalate, C1-6 alkoxy C1-12 alkyl phthalates such as dimethoxyethyl phthalate, C1-12 alkyl-aryl-C1-3 alkyl phthalates such as butyl benzyl phthalate, C1-6 alkylphthalyl C2-4 alkylene glycolates such as ethylphthalyl ethylene glycolate and butylphthalyl butylene glycolate, tri-C1-12 alkyl trimellitates such as trimethyl trimellitate, triethyl trimellitate, trioctyl trimellitate, and tri-2- ethylhexyl trimellitate, and tetra-C1-12 alkyl pyromellitates such as tetraoctyl pyromellitate), fatty acid esters (e.g., adipic acid esters such as dibutyl adipate, dioctyl adipate, butoxyethoxy ethyl benzyl adipate, and dibutoxyethoxy ethyl adipate, azelaic acid esters such as diethyl azelate, dibutyl azelate, and dioctyl azelate, sebacic acid esters such as dibutyl sebacate and dioctyl sebacate, butyl oleate, and methyl acetyl ricinoleate), short-chain fatty acid esters of polyhydric alcohols (e.g., glycerine, trimethylol propane, pentaerythritol, and sorbitol) [e.g., triacetin and diglycerin tetraacetate], glycol esters (e.g., dipropylene glycol dibenzoate), citric acid esters (e.g., acetyl tributyl citrate); ester oligomers (e.g., caprolactone oligomer), and phosphoric acid esters.

[0028] According to an embodiment of the invention there is provided a mouthpiece element for an aerosol-generating article. The mouthpiece element may comprise a tipping wrapper, preferably a tipping paper, enclosing a filter portion. The filter portion may comprise a filter rod comprising a filter material. The filter rod may have a density of between about 5 kilograms per cubic meter and 50 kilograms per cubic meter.

[0029] According to an embodiment of the invention there is provided a mouthpiece element for an aerosol-generating article. The mouthpiece element comprises a tipping wrapper, preferably a tipping paper, enclosing a filter portion. The filter portion comprises a filter rod comprising a filter material. The filter rod comprising the filter material has a density of between about 5 kilograms per cubic meter and 50 kilograms per cubic meter.

[0030] The filter portion may be a cylindrical filter portion. The filter portion may be a tubular filter portion.

[0031] The filter material having a density of between about 5 kilograms per cubic meter and 50 kilograms per cubic meter may enhance airflow through the mouthpiece element. The filter material having a density of between about 5 kilograms per cubic meter and 50 kilograms per New PCT Patent Application December 15, 2025 Philip Morris Products S.A. 46236-PCT

[0032] -5- cubic meter may reduce the filtration of one or both of active substances and humectants. The filter material having a density of between about 5 kilograms per cubic meter and 50 kilograms per cubic meter may prevent over-filtration.

[0033] The filter material may comprise or may consist of a crimped sheet of material. The filter material may comprise or may consist of crimped paper. The filter material may comprise or may consist of bleached or unbleached crimped paper. As used herein, the terms “crimped sheet” or “crimped paper” denote a sheet or paper having a plurality of substantially parallel ridges or corrugations.

[0034] The crimped paper may comprise activated carbon.

[0035] The crimped paper may comprise one or more alkali salts. The one or more alkali salts may be selected from lithium salt, sodium salt, potassium salt, and mixtures thereof.

[0036] The crimped paper may have a basis weight of between about 25 grams per square meter and about 50 grams per square meter.

[0037] The crimped paper may be a low density paper. The crimped paper may have a width of between 100mm and 300mm, preferably a width of between 100mm and 200mm.

[0038] The crimped paper may be made from wood-free pulp. The wood-free pulp may be selected from the group consisting of flax pulp, bamboo pulp, reeds pulp, jute pulp, hemp pulp, pineapple pulp, and mixtures thereof.

[0039] The filter material may comprise organic fibers. The organic fibers may be selected from the group consisting of tea fibers, bamboo fibers, hemp fibers, cotton fibers, flax fibers, ramie fibers, jute fibers, coir fibers, kenaf fibers, abaca fibers, wool fibers, silk fibers, lyocell fibers, modal fibers, SeaCell fibers, mycelium composites, algae fibers, and seaweed fibers.

[0040] The organic fibers may be selected from the group consisting of tea fibers, bamboo fibers, hemp fibers, cotton fibers, and mixtures thereof.

[0041] The tea fibers may be selected from green tea fibers, black tea fibers, oolong tea fibers, white tea fibers, herbal tea fibers, and mixtures thereof.

[0042] The fibers may be comprised in a bag. The fibers may be comprised in a biodegradable bag. The bag may be a paper bag or a perforated polylactic acid (PLA) bag.

[0043] The use of low-compacted materials such as crimped paper or tea fibers within the mouthpiece may contribute to environmental sustainability through biodegradability. The use of low-compacted materials such as crimped paper or tea fibers within the mouthpiece may optimize the mouthpiece's weight and material use, offering a cost-effective solution.

[0044] According to an embodiment of the invention there is provided a mouthpiece element for an aerosol-generating article. The mouthpiece element may comprise a tipping wrapper, preferably a tipping paper, enclosing a hollow tubular filter portion. The hollow tubular filter portion may comprise an inner wall having an inner diameter dFP. The hollow tubular filter New PCT Patent Application December 15, 2025 Philip Morris Products S.A. 46236-PCT

[0045] -6- portion may comprise a proximal end and a distal end defining a longitudinal axis. The mouthpiece element may comprise a disc-like flange extending perpendicular to the longitudinal axis of the hollow tubular filter portion. The disc-like flange may comprise an outer rim with an outer diameter dfiange. The disc-like flange may comprise a central orifice having an inner diameter dorifice. The outer diameter of the disc-like flange dfiange may correspond to the inner diameter of the hollow tubular filter portion dpp.

[0046] According to an embodiment of the invention there is provided a mouthpiece element for an aerosol-generating article. The mouthpiece element comprises a tipping wrapper, preferably a tipping paper, enclosing a hollow tubular filter portion. The hollow tubular filter portion comprises an inner wall having an inner diameter dpp. The hollow tubular filter portion comprises a proximal end and a distal end defining a longitudinal axis. The mouthpiece element comprises a disc-like flange extending perpendicular to the longitudinal axis of the hollow tubular filter portion. The disc-like flange comprises an outer rim with an outer diameter dfiange. The disc-like flange comprises a central orifice having an inner diameter dorifice. The outer diameter of the disc-like flange dfiange corresponds to the inner diameter of the hollow tubular filter portion dpp.

[0047] The mouthpiece element with the disc-like flange may enhance airflow through the mouthpiece element. The mouthpiece element with the disc-like flange may reduce the filtration of one or both of active substances and humectants. The mouthpiece element with the disc-like flange may prevent over-filtration.

[0048] The inner diameter dorifice of the central orifice may be between 1 millimeter and 4 millimeters, preferably between 2 millimeters and 3 millimeters.

[0049] The disc like flange may comprise a plurality of flaps. The flaps may extend perpendicular to the longitudinal axis. The flaps may extend from the inner wall of the hollow tubular filter portion outer rim towards the central orifice. The flaps may extend from the outer rim towards the central orifice.

[0050] The flaps may be triangular. The disc like flange may comprise 4 or more, preferably 6 or more, more preferably 8 or more triangular flaps. The triangular flaps may be peripherally arranged. The flaps may extend from the outer rim inwards. The triangular flaps may abut or overlap to form the disc-like flange. The triangular flaps may have rounded tips to form the central orifice.

[0051] The disc-like flange may comprise or be made from paper or cardboard. The disc-like flange may comprise or be made from tipping paper or paper overwrap material.

[0052] The disc-like flange may comprise or be made from moldable, non-air permeable materials, including biodegradable options and other polymers such as paperboard, PI_A (polylactic acid), biodegradable plastics, cellulose acetate, polyethylene (PE), polypropylene New PCT Patent Application December 15, 2025 Philip Morris Products S.A. 46236-PCT

[0053] -7-

[0054] (PP), polystyrene (PS), polyethylene terephthalate (PET), polyvinyl chloride (PVC), acrylonitrile butadiene styrene (ABS), polyamide (Nylon), polycarbonate (PC), polyurethane (Pll), PEEK (polyether ether ketone), PEN (polyethylene naphthalate), PBT (polybutylene terephthalate), PMMA (polymethyl methacrylate), thermoplastic elastomers (TPE), thermoplastic polyurethane (TPU), HDPE (high-density polyethylene), LDPE (low-density polyethylene), HIPS (high-impact polystyrene), and EVA (ethylene-vinyl acetate).

[0055] The disc-like flange may comprise or be made from paper or cardboard. The disc-like flange may comprise or be made from tipping paper or paper overwrap material.

[0056] The disc-like flange may be provided as an insert.

[0057] The hollow tubular filter portion may comprise a tube and the disc-like flange may be provided as an insert in the tube. The tube may, at the same time, be the tipping wrapper of the mouthpiece element.

[0058] The mouthpiece element may comprise a hollow cardboard tube designed to retain the insert internally, for example affixed in place with an adhesive. Notably, the positioning of the insert may vary. The insert may be arranged at the proximal end to directly contact with the user's lips. The insert may be recessed and set back from the proximal end. The insert may be positioned at the distal end of the mouthpiece element to be placed adjacent to an aerosolforming substrate portion of an aerosol-generating article.

[0059] Materials suitable for the tube may be the same as described above for the disc-like flange. The tube may be a cardboard tube. The tube and the disc-like flange may be made from the same material or materials. The hollow tubular filter portion and the disc-like flange may be made from the same material or materials.

[0060] The disc-like flange may be configured to abut a proximal end of the hollow tubular filter portion. The disc-like flange may be positioned at the proximal end of the hollow tubular filter portion.

[0061] The disc-like flange and the tipping wrapper may be a monolithic element.

[0062] The disc-like flange may be formed by inwardly bending an excess of overwrap material. The central orifice may be formed using a threaded mandrel. The disc-like flange may be formed by inwardly bending an excess portion of the tipping wrapper, the excess portion extending beyond a proximal end of the filter portion.

[0063] The disc-like flange may be recessed from the proximal end of the hollow tubular filter portion. The disc-like flange may be recessed by a distance of 2 mm to 3 mm from the proximal end of the hollow tubular filter portion.

[0064] The disc-like flange may be arranged at a center portion of the mouthpiece element between the proximal end and the distal end of the mouthpiece element. The disc-like flange New PCT Patent Application December 15, 2025 Philip Morris Products S.A. 46236-PCT

[0065] -8- may be arranged at a center portion of the hollow tubular filter portion between the proximal end and the distal end of the hollow tubular filter portion.

[0066] The disc-like flange may be arranged at the distal end of the mouthpiece element. The disc-like flange may be arranged at the distal end of the hollow tubular filter portion.

[0067] The disc-like flange may be attached to the inner wall of the hollow tubular filter portion. The disc-like flange may be attached to the inner wall of the hollow tubular filter portion by one or more of a form fit and an adhesive.

[0068] According to an embodiment of the invention there is provided a mouthpiece element for an aerosol-generating article. The mouthpiece element may comprise a tipping wrapper, preferably a tipping paper, enclosing a filter portion. The filter portion may have a diameter. The filter portion may have a proximal end and a distal end defining a longitudinal axis. The filter portion may comprise a filter material. The filter material may have a longitudinally arranged slit extending from the proximal end to the distal end in a direction parallel to the longitudinal axis of the filter portion. The slit may have a width and a height, each in a direction perpendicular to the longitudinal axis of the filter portion and perpendicular to each other. The slit may be configured to be opened by applying a compressive force in the width direction of the slit.

[0069] According to an embodiment of the invention there is provided a mouthpiece element for an aerosol-generating article. The mouthpiece element comprises a tipping wrapper, preferably a tipping paper, enclosing a filter portion. The filter portion has a diameter. The filter portion has a proximal end and a distal end defining a longitudinal axis. The filter portion comprises a filter material. The filter material has a longitudinally arranged slit extending from the proximal end to the distal end in a direction parallel to the longitudinal axis of the filter portion. The slit has a width and a height, each in a direction perpendicular to the longitudinal axis of the filter portion and perpendicular to each other. The slit is configured to be opened by applying a compressive force in the width direction of the slit.

[0070] The slit may be configured to be closed when no compressive force is applied. The slit may be configured to be closed when no compressive force is applied on the tipping wrapper enclosing the filter portion.

[0071] The slit is configured to be closed when no compressive force is applied. The slit is configured to be closed when no compressive force is applied on the tipping wrapper enclosing the filter portion.

[0072] The filter portion may be a cylindrical filter portion. The filter portion may be a tubular filter portion.

[0073] The openable slit may enhance airflow through the mouthpiece element. The openable slit may reduce the filtration of one or both of active substances and humectants. The openable New PCT Patent Application December 15, 2025 Philip Morris Products S.A. 46236-PCT

[0074] -9- slit may prevent over-filtration. The openable slit may provide a dynamic mouthpiece element. The openable slit may allow for a user to open the slit or not depending on her or his preferences. The openable slit may allow for a user to change filtration properties depending on her or his preferences.

[0075] The presence of the slit may allow an option for the consumer to apply compressive force via a pinching motion, and thus causing transverse deformation of the filter to open up the slit and creating an air passage that may allow a direct passage for aerosol to pass through the mouthpiece.

[0076] A ratio of the width of the slit to the height of the slit may be between 1 / 50 and 1 / 10.

[0077] The slit may be cut via laser. The slit may be created by combing two hemispherical components without central adhesion.

[0078] The slit may have a width of 0.3 mm or less, preferably 0.2 mm or less, more preferably 0.1 mm or less. The slit may be completely closed in the closed configuration. The slit may be completely closed when no compressive force is applied on the filter portion. The slit may be completely closed when no compressive force is applied on the tipping wrapper enclosing the filter portion. The slit may be completely closed when no compressive force is on the tipping wrapper that causes transverse deformation of the filter to open up the slit.

[0079] The slit may be configured to be closed when no compressive force is applied and configured to be opened by applying a compressive force.

[0080] This slit may be very fine, for example 0.2 mm or less, and therefore may have a negligible effect on airflow and aerosol delivery in its closed position.

[0081] The slit may have a height of about 1 / 3 to about 4 / 5 of the diameter of the filter portion.

[0082] The filter material may be a cellulose-based filter material. The filter material may comprise or consist of cellulose acetate. The filter material may comprise or consist of cellulose acetate and triacetin.

[0083] The filter material may be configured such that the slit remains at least partially open after removal of the compressive force. An aerosol may pass relatively unhindered through the opened or at least partially opened slit, thereby reducing a retention to draw of the aerosolgenerating article.

[0084] The slit may remain at least partially open for 30 minutes or more.

[0085] According to an embodiment of the invention there is provided a mouthpiece element for an aerosol-generating article. The mouthpiece element may comprise a tipping wrapper, preferably a tipping paper, enclosing a filter portion. The filter portion may comprise a filter material. The filter portion may have a circumference. The filter portion may have a proximal end and a distal end defining a longitudinal axis. The filter portion may be attached to the New PCT Patent Application December 15, 2025 Philip Morris Products S.A. 46236-PCT

[0086] -10- tipping wrapper along a first fixation line and along a second fixation line. Each of the first and second fixation lines may extend from the proximal end to the distal end in a direction parallel to the longitudinal axis of the filter portion on the circumference. The first fixation line may be located opposite to the second fixation line.

[0087] According to an embodiment of the invention there is provided a mouthpiece element for an aerosol-generating article. The mouthpiece element comprises a tipping wrapper, preferably a tipping paper, enclosing a filter portion. The filter portion comprises a filter material. The filter portion has a circumference. The filter portion has a proximal end and a distal end defining a longitudinal axis. The filter portion is attached to the tipping wrapper along a first fixation line and along a second fixation line. Each of the first and second fixation lines extends from the proximal end to the distal end in a direction parallel to the longitudinal axis of the filter portion on the circumference. The first fixation line is located opposite to the second fixation line.

[0088] The filter portion may be a cylindrical filter portion. The filter portion may be a tubular filter portion.

[0089] The mouthpiece element with the first and second fixation lines may enhance airflow through the mouthpiece element. The mouthpiece element with the first and second fixation lines may reduce the filtration of one or both of active substances and humectants. The mouthpiece element with the first and second fixation lines may prevent over-filtration. The mouthpiece element with the first and second fixation lines may provide a dynamic mouthpiece element. The mouthpiece element with the first and second fixation lines may allow for a user to change filtration properties depending on her or his preferences.

[0090] A compressive force may be applied by a user via a pinching motion to the mouthpiece element to press the filter portion into an oval form. As the filter portion is attached to the tipping wrapper only along the first fixation line and along the second fixation line, when the pressing force is no longer applied, the filter material may retain ovality, whilst the tipping wrapper may return to a more circular shape. Thereby, two air channels may be provided.

[0091] The first fixation line and the second fixation line each may have a width of about 1 / 20 to about 1 / 5 of the circumference of the filter portion. The width may be measured along the circumference in a direction perpendicular to the longitudinal axis.

[0092] The first and second fixation lines may comprise an adhesive.

[0093] The filter material may be a cellulose-based filter material. The filter material may comprise or consist of cellulose acetate. The filter material may comprise or consist of cellulose acetate and triacetin.

[0094] The filter material may have a lower elasticity than the tipping wrapper enclosing the tubular filter portion. This deliberate mismatch in elasticities may enhance creating two New PCT Patent Application December 15, 2025 Philip Morris Products S.A. 46236-PCT

[0095] -11- channels that promote an airflow through the mouthpiece element and may prevent undesired over-filtration of active substances and humectants.

[0096] According to an embodiment of the invention there is provided an aerosol-generating article comprising at least one mouthpiece element as disclosed herein and an aerosol-forming substrate. The aerosol-generating article may be a HNB (heat-not-burn) article. The aerosolforming substrate may comprise an aerosol-former content of more than 5 percent by weight. The aerosol-forming substrate may be part of an aerosol-forming substrate portion of the aerosol-generating article. The aerosol-forming substrate portion may be located upstream of the mouthpiece element. The mouthpiece element may be located at a downstream end or proximal end of the aerosol-generating article. The aerosol-generating article may comprise a susceptor element. The susceptor element may be provided within or around the aerosolforming substrate. The aerosol-generating article may comprise a front plug at a distal end of the article. The front plug may comprise a filter material. The front plug may be identical to a mouthpiece element as disclosed herein. The aerosol-generating article may comprise two mouthpiece elements as disclosed herein. The aerosol-generating article may comprise a first mouthpiece element as disclosed herein provided at a proximal end of the article and a second mouthpiece element as disclosed herein provided at a proximal end of the article

[0097] A pressure differential (RTD - resistance to draw) across the aerosol-generating article may be about 150 mmWC (millimeters of water column) or less. A pressure differential (RTD - resistance to draw) across the aerosol-generating article may be about 30 mmWC or more.

[0098] According to an embodiment of the invention there is provided an aerosol-generating system comprising an aerosol generating device and an aerosol-generating article comprising a mouthpiece element as disclosed herein.

[0099] According to an embodiment of the invention there is provided a method for manufacturing a patterned filter portion. The method may comprise providing a continuous tow of cellulose-based material. The method may comprise feeding the continuous tow into a steam die having a patterned cross-section. The method may comprise pulling the continuous tow through the die. The method may comprise drying the tow, preferably by blowing hot air onto the tow. The method may comprise cutting the tow.

[0100] According to an embodiment of the invention there is provided a method for manufacturing a patterned filter portion. The method comprises providing a continuous tow of cellulose-based material. The method comprises feeding the continuous tow into a steam die having a patterned cross-section. The method comprises pulling the continuous tow through the die. The method comprises drying the tow, preferably by blowing hot air onto the tow. The method comprises cutting the tow.

[0101] The cellulose-based material may comprise cellulose acetate. New PCT Patent Application December 15, 2025 Philip Morris Products S.A. 46236-PCT

[0102] -12-

[0103] The steam die may have a cross-sectional profile which is the same as the profile of the desired cross-sectional pattern of the filter portion of the mouthpiece element. The steam die may taper down to the size and shape of cross section that is required. As the tow passes through the die, it may be formed and partially cured to form the shape required. There may be more than one steam die which may be followed by a number of drying stations which blow hot air onto the rod to remove any excess steam / moisture. The rod may then be fed into a cutting device where it is pulled through and cut to the desired length.

[0104] According to an embodiment of the invention there is provided a method for manufacturing a mouthpiece element for an aerosol-generating article. The method may comprise the method for manufacturing a patterned filter portion as described herein. The mouthpiece element may be a mouthpiece element as described herein.

[0105] According to an embodiment of the invention there is provided a method for manufacturing an aerosol-generating article. The method may comprise the method for manufacturing a patterned filter portion as disclosed herein. The method may comprise the method for manufacturing a mouthpiece element as described herein. The aerosol-generating article may be an aerosol-generating article as described herein.

[0106] As used herein, the tipping wrapper of the mouthpiece element may be a tubular element. The tipping wrapper may be a tube, for example a cardboard tube. The tipping wrapper may be a monolithic tube. The tipping wrapper may be a hollow tube. The tipping wrapper may be a monolithic hollow tube. The tipping wrapper may be a rolled sheet of material. The tipping wrapper may be made of a paper-based material. The tipping wrapper may be a tipping paper.

[0107] The mouthpiece element of the invention may provide a mouthpiece element with reduced filtration. The innovation may address the issue of excessive filtering inherent in traditional tobacco product designs when applied to modern devices like heat-not-burn (HnB) products. This tailored approach may ensure that active ingredients are delivered more efficiently to the user, optimizing the consumption experience by preventing the unnecessary waste of active substances.

[0108] The mouthpiece element of the invention may allow to reduce the amount of filtering material without compromising on filtration efficacy. The mouthpiece element of the invention may effectively filter out unwanted substances while ensuring that desired active ingredients, like nicotine and humectants, are delivered to the user.

[0109] The mouthpiece element of the invention is compatible with a wide range of aerosolgenerating devise and aerosol-generating articles, including those utilizing external and internal heating mechanisms. New PCT Patent Application December 15, 2025 Philip Morris Products S.A. 46236-PCT

[0110] -13-

[0111] As used herein, the term “aerosol-forming substrate” relates to a substrate capable of releasing volatile compounds that can form an aerosol or a vapor. Such volatile compounds may be released by heating the aerosol-forming substrate. The aerosol-forming substrate may be in solid form or may be in liquid form. The aerosol-forming substrate may be solid or liquid or may comprise both solid and liquid components. An aerosol-forming substrate may be part of an aerosol-generating article. The terms “aerosol” and “vapor” are used synonymously.

[0112] The aerosol-forming substrate may comprise nicotine. The nicotine-containing aerosolforming substrate may be a nicotine salt matrix.

[0113] The aerosol-forming substrate may comprise plant-based material. The aerosolforming substrate may comprise tobacco. The aerosol-forming substrate may comprise a tobacco-containing material including volatile tobacco flavour compounds which are released from the aerosol-forming substrate upon heating. Alternatively, the aerosol-forming substrate may comprise a non-tobacco material. The aerosol-forming substrate may comprise homogenised plant-based material. The aerosol-forming substrate may comprise homogenised tobacco material. Homogenised tobacco material may be formed by agglomerating particulate tobacco. In a particularly preferred embodiment, the aerosol-forming substrate may comprise a gathered crimped sheet of homogenised tobacco material. As used herein, the term 'crimped sheet' denotes a sheet having a plurality of substantially parallel ridges or corrugations.

[0114] The aerosol-forming substrate may comprise at least one aerosol former. An aerosolformer is any suitable known compound or mixture of compounds that, in use, facilitates formation of a dense and stable aerosol and that is substantially resistant to thermal degradation at the temperature of operation of the device. Suitable aerosol formers are well known in the art and include, but are not limited to: polyhydric alcohols, such as triethylene glycol, 1 ,3-butanediol and glycerine; esters of polyhydric alcohols, such as glycerol mono-, di- or triacetate; and aliphatic esters of mono-, di- or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate. Preferred aerosol formers are polyhydric alcohols or mixtures thereof, such as triethylene glycol, 1 , 3-butanediol. Preferably, the aerosol former is glycerine. Where present, the homogenised tobacco material may have an aerosol former content of equal to or greater than 5 percent by weight on a dry weight basis, and preferably from 5 percent to 30 percent by weight on a dry weight basis. The aerosol-forming substrate may comprise other additives and ingredients, such as flavourants.

[0115] Preferably, the aerosol-forming substrate comprises plant material and an aerosol former. Preferably, the plant material is a plant material comprising an alkaloid, more preferably a plant material comprising nicotine, and more preferably a tobacco-containing material. New PCT Patent Application December 15, 2025 Philip Morris Products S.A. 46236-PCT

[0116] -14-

[0117] Preferably, the aerosol-forming substrate comprises at least 70 percent of plant material, more preferably at least 90 percent of plant material by weight on a dry weight basis. Preferably, the aerosol-forming substrate comprises less than 95 percent of plant material by weight on a dry weight basis, such as from 90 to 95 percent of plant material by weight on a dry weight basis.

[0118] Preferably, the aerosol-forming substrate comprises at least 5 percent of aerosol former, more preferably at least 10 percent of aerosol former by weight on a dry weight basis. Preferably, the aerosol-forming substrate comprises less than 30 percent of aerosol former by weight on a dry weight basis, such as from 5 to 30 percent of aerosol former by weight on a dry weight basis.

[0119] As used herein, the term “aerosol-generating article” refers to an article comprising an aerosol-forming substrate that is capable of releasing volatile compounds that can form an aerosol. An aerosol-generating article may be disposable. An aerosol-generating article comprising an aerosol-forming substrate comprising tobacco may be referred to herein as a tobacco stick.

[0120] As used herein, the term “aerosol-generating device” refers to a device that interacts with an aerosol-forming substrate to generate an aerosol. An aerosol-generating device may interact with one or both of an aerosol-generating article comprising an aerosol-forming substrate, and a cartridge comprising an aerosol-forming substrate. In some examples, the aerosol-generating device may heat the aerosol-forming substrate to facilitate release of volatile compounds from the substrate. An electrically operated aerosol-generating device may comprise an atomiser, such as an electric heater, to heat the aerosol-forming substrate to form an aerosol.

[0121] As used herein, the term "aerosol-generating system" refers to the combination of an aerosol-generating device with an aerosol-forming substrate. When the aerosol-forming substrate forms part of an aerosol-generating article, the aerosol-generating system refers to the combination of the aerosol-generating device with the aerosol-generating article. In the aerosol-generating system, the aerosol-forming substrate and the aerosol-generating device cooperate to generate an aerosol.

[0122] As used herein, the terms “upstream” and “front”, and “downstream” and “rear”, are used to describe the relative positions of components, or portions of components, of the aerosol generating article in relation to the direction in which airflows through the aerosol generating article during use thereof. Aerosol generating articles according to the invention comprise a proximal end through which, in use, an aerosol exits the article. The proximal end of the aerosol generating article may also be referred to as the mouth end or the downstream end. The mouth end is downstream of the distal end. The distal end of the aerosol generating New PCT Patent Application December 15, 2025 Philip Morris Products S.A. 46236-PCT

[0123] -15- article may also be referred to as the upstream end. Components, or portions of components, of the aerosol generating article may be described as being upstream or downstream of one another based on their relative positions between the proximal end of the aerosol generating article and the distal end of the aerosol generating article. The front of a component, or portion of a component, of the aerosol generating article is the portion at the end closest to the upstream end of the aerosol generating article. The rear of a component, or portion of a component, of the aerosol generating article is the portion at the end closest to the downstream end of the aerosol generating article.

[0124] As used herein, the term “longitudinal” refers to the direction corresponding to the main longitudinal axis of the aerosol-generating article, which extends between the upstream and downstream ends of the aerosol-generating article.

[0125] The term “length” denotes the dimension of a component of the aerosol-generating article in the longitudinal direction. For example, it may be used to denote the dimension of the rod or of the elongate tubular elements in the longitudinal direction.

[0126] As used herein with reference to the present invention, the term “transverse” is used to describe the direction perpendicular to the longitudinal direction. Unless otherwise stated, references to the “cross-section” of the aerosol-generating article or a component of the aerosol-generating article refer to the transverse cross-section.

[0127] As used herein, the term “proximal” refers to a user-end, or mouth-end of the aerosolgenerating article, and the term “distal” refers to the end opposite to the proximal end.

[0128] Components of aerosol-generating articles according to the present invention may be described as being upstream or downstream of one another based on their relative positions between the proximal end of the aerosol-generating article and the distal end of the aerosolgenerating article.

[0129] The aerosol-generating device suitable for use with an aerosol-generating article as described herein may comprise a cavity for receiving at least part of the aerosol-generating article and a heater for heating the aerosol-forming substrate portion of the aerosol-generating article when the aerosol-generating article is received within the cavity. The cavity may be a heating chamber.

[0130] Below, there is provided a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more features of another example, embodiment, or aspect described herein.

[0131] Example 1. A mouthpiece element for an aerosol-generating article, New PCT Patent Application December 15, 2025 Philip Morris Products S.A. 46236-PCT

[0132] -16- wherein the mouthpiece element comprises a tipping wrapper enclosing a filter portion, wherein the filter portion has a diameter, a proximal end and a distal end defining a longitudinal axis, wherein the filter portion comprises a filter material, wherein the filter material has a longitudinally arranged slit extending from the proximal end to the distal end in a direction parallel to the longitudinal axis of the filter portion, wherein the slit has a width and a height, each in a direction perpendicular to the longitudinal axis of the filter portion and perpendicular to each other, and wherein the slit is configured to be opened by applying a compressive force in the width direction of the slit.

[0133] Example 2. The mouthpiece element according to example 1, wherein the ratio of the width of the slit to the height of the slit is 1 / 50 to about 1 / 10.

[0134] Example 3. The mouthpiece element according to any of preceding examples 1 to

[0135] 2, wherein the slit has a width of 0.53 mm or less, preferably 0.2 mm or less.

[0136] Example 4. The mouthpiece element according to any of preceding examples 1 to

[0137] 3, wherein the slit has a height of about 1 / 3 to about 4 / 5 of the diameter of the filter portion.

[0138] Example 5. The mouthpiece element according to any of preceding examples 1 to

[0139] 4, wherein the filter material comprises cellulose acetate, preferably cellulose acetate and triacetin, preferably consists of cellulose acetate and triacetin.

[0140] Example 6. The mouthpiece element according to any of the preceding examples, wherein the slit is configured to be closed when no compressive force is applied.

[0141] Example 7. The mouthpiece element according to any of the preceding examples, wherein the slit is configured to be closed when no compressive force is applied on the tipping wrapper enclosing the filter portion.

[0142] Example 8. A mouthpiece element for an aerosol-generating article, wherein the mouthpiece element comprises a tipping wrapper enclosing a filter portion, New PCT Patent Application December 15, 2025 Philip Morris Products S.A. 46236-PCT

[0143] -17- wherein the filter portion comprises a filter material, wherein the filter portion has a circumference, a proximal end and a distal end defining a longitudinal axis, wherein the filter portion is affixed to the tipping wrapper along a first fixation line and along a second fixation line each extending from the proximal end to the distal end in a direction parallel to the longitudinal axis of the filter portion on the circumference, wherein the first fixation line is opposite to the second fixation line.

[0144] Example 9. The mouthpiece element according to example 8, wherein the first fixation line and the second fixation line has a width of about 1 / 20 to about 1 / 5 of the circumference of the filter portion.

[0145] Example 10. The mouthpiece element according to any of preceding examples 8 to

[0146] 9, wherein the first and second fixation lines comprise an adhesive.

[0147] Example 11. The mouthpiece element according to any of preceding examples 8 to

[0148] 10, wherein the filter material comprises cellulose acetate, preferably cellulose acetate and triacetin, preferably consists of cellulose acetate and triacetin.

[0149] Example 12. A mouthpiece element for an aerosol-generating article, wherein the mouthpiece element comprises a tipping wrapper enclosing a filter portion, wherein the filter portion has a proximal end and a distal end defining a longitudinal axis, wherein the filter portion comprises a filter material and one or more longitudinally arranged hollow airflow passageways extending in a direction parallel to the longitudinal axis of the filter portion, wherein the filter portion has a cross-sectional pattern formed by the filter material and the one or more longitudinally arranged hollow airflow passageways, and wherein the cross-sectional pattern is non-circular.

[0150] Example 13. The mouthpiece element according to example 12, wherein the cross- sectional pattern is constant along the longitudinal axis of the filter portion.

[0151] Example 14. The mouthpiece element according to example 12, wherein the filter portion comprises two or more different cross-sectional patterns along the longitudinal axis of the filter portion. New PCT Patent Application December 15, 2025 Philip Morris Products S.A. 46236-PCT

[0152] -18-

[0153] Example 15. The mouthpiece element according to any of the preceding examples 12 to 14, wherein the non-circular cross-sectional pattern comprises one or more geometrical shapes of: circles having two or more perimetral groves, regular or irregular polygons, semicircles, cog or gear shapes, hole circles of four or more circles, and regular or irregular polygonal stars.

[0154] Example 16. The mouthpiece element according to any of the preceding examples 12 to 15, wherein 60 % or more, preferably 70 % or more of the cross-sectional pattern are formed by the filter material and 40 % or less, preferably 30 % or less of the cross-sectional pattern are formed by the one or more airflow passageways.

[0155] Example 17. The mouthpiece element according to any of the preceding examples 12 to 16, wherein the filter material is in the form of filaments, fibers, webs and / or extrusions.

[0156] Example 18. The mouthpiece element according to any of the preceding examples 12 to 17, wherein the filter material comprises cellulosic material.

[0157] Example 19. The mouthpiece element according to any of the preceding examples 12 to 18, wherein the filter material comprises a plasticizer, preferably an ester-based plasticizer, wherein the filter material preferably comprises the plasticizer in an amount of 8 wt- % or more, more preferably in an amount of 15 wt-% or more, even more preferably in an amount of 22 wt-% or more.

[0158] Example 20. A mouthpiece element for an aerosol-generating article, wherein the mouthpiece element comprises a tipping wrapper enclosing a filter portion, wherein the filter portion comprises a filter rod comprising a filter material, and wherein the filter rod comprising the filter material has a density of between

[0159] 5 kg / m3and 50 kg / m3.

[0160] Example 21. The mouthpiece element according to example 20, wherein the filter material is bleached or unbleached crimped paper.

[0161] Example 22. The mouthpiece element according to example 21 , wherein the crimped paper further comprises activated carbon. New PCT Patent Application December 15, 2025 Philip Morris Products S.A. 46236-PCT

[0162] -19-

[0163] Example 23. The mouthpiece element according to any of examples 21 or 22, wherein the crimped paper further comprises an alkali salt, preferably selected from lithium salt, sodium salt, potassium salt, and mixtures thereof.

[0164] Example 24. The mouthpiece element according to any of the preceding examples 21 to 23, wherein the crimped paper has a basis weight of about 25 to about 50 g / m2.

[0165] Example 25. The mouthpiece element according to any of the preceding examples 21 to 24, wherein the crimped paper is made from wood-free pulp, wherein the wood-free pulp is preferably selected from the group consisting of flax pulp, bamboo pulp, reeds pulp, jute pulp, hemp pulp, pineapple pulp, and mixtures thereof.

[0166] Example 26. The mouthpiece element according to example 20, wherein the filter material comprises organic fibers, preferably selected from the group consisting of tea fibers, bamboo fibers, hemp fibers, cotton fibers, and mixtures thereof.

[0167] Example 27. The mouthpiece element according to example 26, wherein the tea fibers are selected from green tea fibers, black tea, fibers, oolong tea fibers, white tea fibers, herbal tea fibers, and mixtures thereof.

[0168] Example 28. The mouthpiece element according to example 26 or 27, wherein the fibers are comprised in a biodegradable bag, preferably a paper bag or a perforated polylactic acid (PLA) bag.

[0169] Example 29. A mouthpiece element for an aerosol-generating article, wherein the mouthpiece element comprises a tipping wrapper enclosing a hollow tubular filter portion having an inner wall having an inner diameter dpp, a proximal end and a distal end defining a longitudinal axis, wherein the mouthpiece element further comprises a disc-like flange extending perpendicular to the longitudinal axis of the hollow tubular filter portion and having an outer rim with an outer diameter dfiange, wherein the disc-like flange further has a central orifice having an inner diameter dorifice, and wherein the outer diameter of the disc-like flange dfiange corresponds to the inner diameter of the hollow tubular filter portion dpp. New PCT Patent Application December 15, 2025 Philip Morris Products S.A. 46236-PCT

[0170] -20-

[0171] Example 30. The mouthpiece element according to example 29, wherein the disc-like flange comprises 4 or more, preferably 6 or more, more preferably 8 or more triangular flaps, wherein the triangular flaps are peripherally arranged at the outer rim and extend from the outer rim inwards, wherein the triangular flaps abut or overlap to form the disc-like flange, and wherein the triangular flaps preferably have rounded tips to form the central orifice.

[0172] Example 31 . The mouthpiece element according to any of preceding examples 29 to

[0173] 30, wherein the disc-like flange comprises or is made from paper or cardboard, preferably from tipping paper or paper overwrap material.

[0174] Example 32. The mouthpiece element according to any of preceding examples 29 to

[0175] 31 , wherein the disc-like flange is configured to abut a proximal end of the hollow tubular filter portion.

[0176] Example 33. The mouthpiece element according to example 32, wherein the disc-like flange is formed by inwardly bending an excess of overwrap paper, wherein the central orifice is formed using a threaded mandrel.

[0177] Example 34. The mouthpiece element according to any of preceding examples 29 to 31 , wherein the disc-like flange is recessed, preferably by a distance of 2 mm to 3 mm from proximal end of the hollow tubular filter portion.

[0178] Example 35. The mouthpiece element according to any of preceding examples 29 to 31 , wherein the disc-like flange is situated at the distal end of the hollow tubular filter portion.

[0179] Example 36. The mouthpiece element according to any of preceding examples 29 to 35, wherein the disc-like flange is affixed to the inner wall of the hollow tubular filter portion, preferably with an adhesive.

[0180] Features described in relation to one embodiment may equally be applied to other embodiments of the invention.

[0181] The invention will be further described, by way of example only, with reference to the accompanying drawings in which:

[0182] Fig. 1a shows an aerosol-generating article; New PCT Patent Application December 15, 2025 Philip Morris Products S.A. 46236-PCT

[0183] -21-

[0184] Figs. 1b to 1d show mouthpiece elements;

[0185] Figs. 2a and 2b show mouthpiece elements;

[0186] Fig. 3a shows a mouthpiece element;

[0187] Figs. 3b and 3c show aerosol-generating articles;

[0188] Figs. 4a to 4f show a mouthpiece element;

[0189] Figs. 5a to 5f show a mouthpiece element; and

[0190] Fig. 6 shows a diagram of particle breakthroughs with different mouthpieces.

[0191] Fig. 1a shows an aerosol-generating article in a cross-sectional view. The article of Fig. 1a comprises a mouthpiece element 10, a hollow tube 12, for example a fine hollow acetate tube, an aerosol-forming substrate portion 14 comprising aerosol-forming substrate, and a front plug 16. The mouthpiece element 10 is located at the downstream end of the article. In other words, the mouthpiece element 10 is located at the proximal end of the article

[0192] The aerosol-forming substrate portion 14 may comprise an optional susceptor. The front plug 16 may be a filter plug. The article comprises at least one outer wrapper. In the embodiment shown, the article comprises two outer wrappers. A distal portion of the article including the aerosol-forming substrate portion 14 is circumscribed by a distal outer wrapper 18 and a proximal portion is circumscribed by a proximal outer wrapper 20.

[0193] An outer diameter of the article may be about 7 millimeters, preferably 7.1 millimeters. A total length of the article may be about 45 millimeters.

[0194] The mouthpiece element 10 may comprise a tipping wrapper 22, preferably a tipping paper, enclosing a filter portion. The tipping wrapper 22 is located coaxially between the filter portion and the proximal outer wrapper 20. Alternatively, the tipping wrapper 22 may be omitted and the at least one outer wrapper, for example the proximal outer wrapper 20, may function as the tipping wrapper enclosing the filter portion of the mouthpiece element 10. The filter portion has a proximal end 24 and a distal end 26 defining a longitudinal axis 28. The filter portion comprises a filter material 30 and one or more longitudinally arranged hollow airflow passageways 32 extending in a direction parallel to the longitudinal axis 28 of the filter portion. The filter portion has a non-circular cross-sectional pattern formed by the filter material 30 and the one or more longitudinally arranged hollow airflow passageways 32. The filter portion may be a cylindrical filter portion. The filter portion may be a tubular filter portion.

[0195] Figs. 1 b to 1 d show top views onto mouthpiece elements 10 with filter portions enclosed by a tipping wrapper 22 and having different non-circular cross-sectional pattern formed by the filter material 30 and the one or more longitudinally arranged hollow airflow passageways 32.

[0196] Fig. 1b shows an embodiment with a non-circular cross-sectional pattern formed by four hollow airflow passageways 32 in form of perimetral groves. A four-fold rotational New PCT Patent Application December 15, 2025 Philip Morris Products S.A. 46236-PCT

[0197] -22- symmetry of the non-circular cross-sectional pattern with respect to the longitudinal axis 28 results, with the longitudinal axis 28 being a longitudinal central axis 28 of the filter portion.

[0198] Fig. 1c shows an embodiment with a non-circular cross-sectional pattern formed by one hollow airflow passageway 32. The one hollow airflow passageway 32 is star-shaped resulting in a five-fold rotational symmetry of the non-circular cross-sectional pattern.

[0199] Fig. 1d shows an embodiment with a non-circular cross-sectional pattern formed by five circular hollow airflow passageways 32 being circumferentially arranged around the longitudinal central axis 28 resulting in a five-fold rotational symmetry of the non-circular cross- sectional pattern.

[0200] Each of the mouthpiece elements 10 of Figs. 1b to 1d may be used as a mouthpiece element 10 in the aerosol-generating article of Fig. 1.

[0201] Fig. 2a shows a top view onto mouthpiece element 10 for an aerosol-generating article. The mouthpiece element 10 comprises a tipping wrapper 22, preferably a tipping paper, enclosing a filter portion. The filter portion comprises a filter rod comprising a filter material 30. The filter rod comprising the filter material 30 may have a density of between 5 kilograms per cubic meter and 50 kilograms per cubic meter.

[0202] The filter material 30 is bleached or unbleached crimped paper. The crimped paper may comprise one or both of activated carbon and an alkali salt. The crimped paper may have a basis weight of about 25 to about 50 grams per square meter. The crimped paper may be made from wood-free pulp.

[0203] Fig. 2b shows a top view onto mouthpiece element 10 for an aerosol-generating article. The mouthpiece element 10 comprises a tipping wrapper 22, preferably a tipping paper, enclosing a filter portion. The filter portion comprises a filter rod comprising a filter material 30. The filter rod comprising the filter material 30 may have a density of between 5 kilograms per cubic meter and 50 kilograms per cubic meter. The filter material 30 comprises organic fibers, preferably selected from the group consisting of tea fibers, bamboo fibers, hemp fibers, cotton fibers, and mixtures thereof. The filter material 30 preferably comprises tea fibers. The fibers may be comprised in a bag. The bag comprising the fibers may be enclosed by the tipping wrapper 22.

[0204] Fig. 3a shows a top view onto mouthpiece element 10. The mouthpiece element 10 comprises a tipping wrapper 22 enclosing a hollow tubular filter portion having an inner wall having an inner hollow filter portion diameter 34 (dFp). The mouthpiece element 10 comprises a proximal end 24 and a distal end 26 defining a longitudinal axis 28 as indicated in Fig. 3b. The mouthpiece element 10 comprises a disc-like flange 36 extending perpendicular to the longitudinal axis 28 of the hollow tubular filter portion and having an outer rim 38 with an outer diameter (dfiange). The disc-like flange 36 has a central orifice 40 having an inner orifice diameter New PCT Patent Application December 15, 2025 Philip Morris Products S.A. 46236-PCT

[0205] -23-

[0206] 42 (dorifice). The outer diameter of the disc-like flange (dfiange) corresponds to the inner diameter of the hollow tubular filter portion 34 (dpp).

[0207] The disc like flange comprises eight substantially triangular flaps 44. The triangular flaps 44 are peripherally arranged at and extend from the outer rim 38 (see Fig. 3b) inwards. The triangular flaps 44 abut or overlap to form the disc-like flange 36. The triangular flaps 44 have rounded tips to form the central orifice 40. The disc-like flange 36 may comprise or be made from paper or cardboard.

[0208] Figs. 3b and 3c show cross-sectional views of aerosol-generating articles comprising the mouthpiece element 10 of Fig. 3a.

[0209] In the embodiment of Fig. 3b, the disc-like flange 36 is located at the proximal end 24 of the mouthpiece element 10. The disc-like flange 36 is configured to abut a proximal end of the hollow tubular filter portion, the disc-like flange 36 may be formed as an insert. In other embodiments, the disc-like flange 36 may be formed by inwardly bending an excess of overwrap material and, optionally, the central orifice 40 may be formed using a threaded mandrel.

[0210] In the embodiment of Fig. 3c, the disc-like flange 36 is recessed from the proximal end of the hollow tubular filter portion. Preferably, the disc-like flange 36 may be formed as an insert. The disc-like flange 36 is located at a center portion of the mouthpiece element 10 between the proximal end 24 and the distal end 26 of the mouthpiece element 10. In the embodiments of Figs. 3b and 3c, the tipping wrapper 22 may be omitted and the at least one outer wrapper, for example the proximal outer wrapper 20, may function as the tipping wrapper enclosing the filter portion of the mouthpiece element 10.

[0211] In the embodiment of Figs. 3b and 3c, preferably, the tipping wrapper 22 is configured as a hollow cardboard tube 22. The disc-like flange 36 may be affixed to the inner wall of the hollow cardboard tube 22, preferably with an adhesive.

[0212] Figs. 4a to 4f show a dynamic mouthpiece element. Figs. 4a, 4c, and 4e show top views. Figs. 4b, 4d, and 4f show perspective views with the individual components being shown semi-transparent for the sake of clarity of illustration.

[0213] Figs. 4a and 4b show the mouthpiece element in a first, initial configuration. The mouthpiece element comprises a tipping wrapper (not shown) enclosing a filter portion. The filter portion has a filter portion diameter 46, a proximal end 24 and a distal end 26 defining a longitudinal axis 28. The filter portion comprises a filter material 30. The filter material comprises a longitudinally arranged slit 48 extending from the proximal end to the distal end in a direction parallel to the longitudinal axis of the filter portion. The slit 48 has a length extending along the longitudinal axis 28. The slit 48 has a width and a height, each in a direction perpendicular to the longitudinal axis 28 of the filter portion and perpendicular to each other. New PCT Patent Application December 15, 2025 Philip Morris Products S.A. 46236-PCT

[0214] -24-

[0215] As shown in Figs. 4a and 4b, the slit 48 is configured to be closed when no compressive force is applied. The slit 48 is configured to be closed when no compressive force is applied on the filter portion. As shown in Figs. 4c and 4d, the slit 48 is configured to be opened by applying a compressive force 50 in the width direction of the slit 48. The compressive force may be applied by a user holding an aerosol-generating article comprising the mouthpiece element in her or his fingers and pressing onto the article.

[0216] The mouthpiece element may be configured such that the slit 48 remains at least partially opened after removal of the compressive force 50 as shown in Figs. 4e and 4f. An aerosol 52 may pass relatively unhindered through the opened or at least partially opened slit 48, thereby reducing a retention to draw of the aerosol-generating article.

[0217] By pressing onto the dynamic mouthpiece filter, a user may control the retention to draw according to her or his preferences. By pressing onto the dynamic mouthpiece filter, a user may prevent undesired over-filtration of active substances and humectants. This operation can be performed at any stage by the user during operation process, or additionally not at all if the user desires the current level of filtration of active substances present in the current mouthpiece element.

[0218] Figs. 5a to 5f show a dynamic mouthpiece element. Figs. 5a, 5c, and 5e show top views. Figs. 5b, 5d, and 5f show perspective views with the individual components being shown semi-transparent for the sake of clarity of illustration.

[0219] Figs. 5a and 5b show the mouthpiece element in a first, initial configuration. The mouthpiece element comprises a tipping wrapper 22 enclosing a filter portion. The filter portion has a circumference, a proximal end 24 and a distal end 26 defining a longitudinal axis 28. The filter portion comprises a filter material 30. The filter portion is affixed to the tipping wrapper 22 along first and second fixation lines 54 extending from the proximal end 24 to the distal end 26 in a direction parallel to the longitudinal axis 28 on opposing sides of the inner surface of the tipping wrapper 22.

[0220] As shown in Figs. 5c and 5d, a user may apply a compressive force 50 to compress the filter element in a direction orthogonal to the longitudinal axis 28. The compressive force may be applied by a user holding an aerosol-generating article comprising the mouthpiece element in her or his fingers and pressing onto the article.

[0221] As shown in Figs. 5e and 5f, after removal of the compressive force 50, the filter portion with filter material 30 maintains its compressed shape mainly at those areas not being attached to the tipping wrapper 22 along first and second fixation lines 54 resulting in gaps 54. An aerosol 54 may pass relatively unhindered through the channels 56, thereby reducing a retention to draw of the aerosol-generating article. New PCT Patent Application December 15, 2025 Philip Morris Products S.A. 46236-PCT

[0222] -25-

[0223] By pressing onto the dynamic mouthpiece filter, a user may control the retention to draw according to her or his preferences. By pressing onto the dynamic mouthpiece filter, a user may prevent undesired over-filtration of active substances and humectants. This operation can be performed at any stage by the user during operation process, or additionally not at all if the user desires the current level of filtration of active substances present in the current mouthpiece element.

[0224] Mouthpiece elements of the invention may enable the delivery of a higher active substance content to the user by offering reduced filtration. This was specifically assessed using a Particle Breakthrough Test (PBT) conducted with an Aerodynamic Particle Size Spectrometer (APS). The test was performed over a duration of 50 seconds at a flow rate of 1.6L / min (HC). The primary objective of this test was to quantify the particles per cubic centimeter (particles / cc) that bypassed the filtration system, aiming to measure the mouthpiece's efficiency in filtering out particulate matter, while facilitating nicotine delivery. Results depicted in Fig. 6 demonstrate that, when integrated into an externally heated aerosol generating system, a mouthpiece element with reduced filtration capabilities ensures the system remains within the limits set by permitted HCHPs (Harmful and Potentially Harmful Constituents) standards.

[0225] Fig. 6 shows the results of the Particle Breakthrough Test (PBT). Fig. 6 shows a diagram of particle breakthroughs using different mouthpiece elements. The vertical axis indicates relative numbers of particles per volume that bypassed the filtration system. Bar 80 shows the relative particle passage using a standard prior art mouthpiece filter, typically a plug of cellulose acetate. Bar 82 indicates particle breakthrough without a mouthpiece filter element. Bar 84 shows the relative particle passage using the mouthpiece element 10 of Fig. 1d. Bar 86 shows the relative particle passage using a flanged mouthpiece element 10 as shown in Fig. 3b or Fig. 3c. Bar 88 shows the relative particle passage using a mouthpiece element of Fig. 2a, wherein the filter material 30 is crimped paper. Bar 90 shows the relative particle passage using a mouthpiece element of Fig. 2b, wherein the filter material 30 is tea in a bag. Bar 92 indicates unhindered particle passage through air in the laboratory.

[0226] Notably, while a significant portion of the aerosol will directly reach a user's mouth in any of the previous embodiments, the mouthpiece element 10 also exhibits filtration capacity. For example, the internal side walls of the outer region, being composed of filter material, reduce the volume of mainstream aerosol emitted by the consumable. The mouthpiece elements of the invention may function as filter elements.

[0227] While filter designs in traditional tobacco products have focused on maximizing filtration, this approach may not be optimal for newer technologies. Traditional filtration principles, when applied to modern devices such as heat-not-burn (HnB) products, can lead to New PCT Patent Application December 15, 2025 Philip Morris Products S.A. 46236-PCT

[0228] -26- excessive filtering. Given the lower operating temperatures of HnB products, the need for intense filtration diminishes. Consequently, current filters may retain too much of the active ingredients, resulting in reduced efficiency. This over-filtration means that a significant portion of these substances is unnecessarily wasted. Those drawbacks may be overcome by the mouthpiece element of the present invention.

Claims

New PCT Patent Application December 15, 2025 Philip Morris Products S.A. 46236-PCT-27-CLAIMS1. A mouthpiece element for an aerosol-generating article, wherein the mouthpiece element comprises a tipping wrapper enclosing a filter portion, wherein the filter portion has a diameter, a proximal end and a distal end defining a longitudinal axis, wherein the filter portion comprises a filter material, wherein the filter material has a longitudinally arranged slit extending from the proximal end to the distal end in a direction parallel to the longitudinal axis of the filter portion, wherein the slit has a width and a height, each in a direction perpendicular to the longitudinal axis of the filter portion and perpendicular to each other, and wherein the slit is configured to be opened by applying a compressive force in the width direction of the slit.

2. The mouthpiece element according to claim 1 , wherein the slit has a width of 0.3 mm or less, preferably 0.2 mm or less.

3. A mouthpiece element for an aerosol-generating article, wherein the mouthpiece element comprises a tipping wrapper enclosing a filter portion, wherein the filter portion comprises a filter material, wherein the filter portion has a circumference, a proximal end and a distal end defining a longitudinal axis, wherein the filter portion is affixed to the tipping wrapper along a first fixation line and along a second fixation line each extending from the proximal end to the distal end in a direction parallel to the longitudinal axis of the filter portion on the circumference, wherein the first fixation line is opposite to the second fixation line.

4. The mouthpiece element according to claim 3, wherein the first fixation line and the second fixation line has a width of about 1 / 20 to about 1 / 5 of the circumference of the filter portion.New PCT Patent Application December 15, 2025 Philip Morris Products S.A. 46236-PCT-28-5. The mouthpiece element according to any of preceding claims 3 to 4, wherein the first and second fixation lines comprise an adhesive.

6. A mouthpiece element for an aerosol-generating article, wherein the mouthpiece element comprises a tipping wrapper enclosing a filter portion, wherein the filter portion has a proximal end and a distal end defining a longitudinal axis, wherein the filter portion comprises a filter material and one or more longitudinally arranged hollow airflow passageways extending in a direction parallel to the longitudinal axis of the filter portion, wherein the filter portion has a cross-sectional pattern formed by the filter material and the one or more longitudinally arranged hollow airflow passageways, and wherein the cross-sectional pattern is non-circular.

7. The mouthpiece element according to claim 6, wherein the filter portion comprises two or more different cross-sectional patterns along the longitudinal axis of the filter portion.

8. The mouthpiece element according to any of claims 6 or 7, wherein the non-circular cross-sectional pattern comprises one or more geometrical shapes of: circles having two or more perimetral groves, regular or irregular polygons, semi-circles, cog or gear shapes, hole circles of four or more circles, and regular or irregular polygonal stars.

9. A mouthpiece element for an aerosol-generating article, wherein the mouthpiece element comprises a tipping wrapper enclosing a filter portion, wherein the filter portion comprises a filter rod comprising a filter material, and wherein the filter rod comprising the filter material has a density of between 5 kg / m3and 50 kg / m3.

10. The mouthpiece element according to claim 9, wherein the filter material is bleached or unbleached crimped paper.

11. The mouthpiece element according to claim 10, wherein the crimped paper is made from wood-free pulp, wherein the wood-free pulp is preferably selected from the group consisting of flax pulp, bamboo pulp, reeds pulp, jute pulp, hemp pulp, pineapple pulp, and mixtures thereof.New PCT Patent Application December 15, 2025 Philip Morris Products S.A. 46236-PCT-29-12. The mouthpiece element according to claim 9, wherein the filter material comprises organic fibers, preferably selected from the group consisting of tea fibers, bamboo fibers, hemp fibers, cotton fibers, and mixtures thereof.

13. A mouthpiece element for an aerosol-generating article, wherein the mouthpiece element comprises a tipping wrapper enclosing a hollow tubular filter portion having an inner wall having an inner diameter dpp, a proximal end and a distal end defining a longitudinal axis, wherein the mouthpiece element further comprises a disc-like flange extending perpendicular to the longitudinal axis of the hollow tubular filter portion and having an outer rim with an outer diameter dfiange, wherein the disc-like flange further has a central orifice having an inner diameter dorifice, and wherein the outer diameter of the disc-like flange dfiange corresponds to the inner diameter of the hollow tubular filter portion dpp.

14. The mouthpiece element according to claim 13, wherein the disc-like flange comprises or is made from paper or cardboard, preferably from tipping paper or paper overwrap material.

15. The mouthpiece element according to any of preceding claims 13 to 14, wherein the disc-like flange is configured to abut a proximal end of the hollow tubular filter portion, or wherein the disc-like flange is recessed, preferably by a distance of 2 mm to 3 mm from the proximal end of the hollow tubular filter portion.

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