Aerosol generating article with reduced pressure drop and enhanced user experience

Abstract

The disclosed aerosol generating article (100) including a main body (101) consists of a mouth filter segment (102), a first bridge segment (104), at least one aerosol generating substrate segment (106), and an upstream segment (108). The mouth filter segment (102) is configured at a downstream end (100-2) of the aerosol generating article (100) to filter an aerosol before the aerosol is inhaled by a user. The first bridge segment (104) is designed to refine an airflow and provide additional filtration. The at least one aerosol generating substrate segment (106) is configured to produce the aerosol. The aerosol generating substrate segment (106) is heated by at least one heater (204) of the aerosol generating device (202). A ventilation arrangement (110) is configured at an upstream end (100-1) of the article (100) to facilitate an airflow from the upstream end (100-1) through the aerosol generating substrate segment (106).

Description

AEROSOL GENERATING ARTICLE WITH REDUCED PRESSURE DROP AND ENHANCED USER EXPERIENCETECHNICAL FIELD

[0001] The present disclosure relates to the field of aerosol generating articles. More particularly, the present disclosure relates to an aerosol generating article with unique ventilation arrangement provided on an upstream end of the aerosol generating article. The ventilation is positioned in a way that it reduces pressure drop across the aerosol generating article resulting in enhanced user experience.BACKGROUND

[0002] Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the present disclosure, or that any publication specifically or implicitly referenced as prior art.

[0003] The aerosol generating article (simply referred to as “article” herein) consists of an aerosol generating substrate for aerosol generation. The aerosol generating substrate segment is heated by various heating methods.

[0004] A typical aerosol generating article contains one or more bridge sections downstream of the aerosol generating substrate segment, each designed with a specific wall thickness. These bridge segments support the aerosol generating article, allow the aerosol to mix uniformly, and do not contribute to the resistance to draw (RTD) of the article, enhancing the ease of inhalation. Following the bridge segments, a filter is incorporated to further refine the aerosol before it reaches the user’s mouth. The bridge segment may also consist of ventilation arrangements to reduce resistance to draw (RTD) further. Additionally, some aerosol generating articles feature an upstream filter segment (also known as a front plug) placed before the aerosol generating substrate. This upstream segment ensures smooth and controlled airflow throughout the device; however, it contributes to RTD. This segment also prevents leakage of condensate into the device cavity.

[0005] The user experience while using such aerosol generating article largely depends on sensorial parameters like mouth-fullness, aerosol temperature, and resistance to draw (RTD). However, many users have reported a lack of sensorial experience while using such aerosol generating articles, which is undesirable. As the aerosol generating substrate is packed into a very small segment of the aerosol generating article, the overall pressure drop remainshigh, leading to a lack of mouth-fullness. Additionally, since the aerosol is generated from a small heating space in which aerosol generating substrate is placed in high density, its temperature often remains undesirable.

[0006] To overcome the high pressure, drop and improve the sensorial experience, the use of ventilation in the aerosol generating article is well known. Normally, these ventilations are provided close to the mouth end (downstream side) of the aerosol generating article, which reduces the effective pressure drop. Ventilation typically involves perforations or air vents integrated into the bridge segments of the article, allowing ambient air to be drawn into the aerosol stream. This provision helps to reduce the pressure drop, lower the overall temperature of the aerosol, and aid in the nucleation process, which volatilizes the aerosolized substances from the substrate. However, introducing ventilation close to the mouthpiece or downstream of the aerosol generating substrate has the potential to dilute the aerosol, leading to a reduced sensorial experience, including a decrease in flavor intensity and smoothness. Therefore, there is a need for improvement in the design of aerosol generating articles to achieve lower pressure drop and better sensorial experience.

[0007] A patent document WO2021170675A1 titled, “Ventilated aerosol-generating article with upstream porous segment” describes an aerosol generating article comprises a rod of an aerosol generating substrate, and a downstream section at a location downstream of the rod of the aerosol generating substrate. The downstream section includes a support element located immediately downstream of the rod. The support element being in longitudinal alignment with the rod and includes a first hollow tubular segment, and an aerosol cooling element located immediately downstream of the support element. The aerosol cooling element being in longitudinal element with the support element and the rod, and including a second hollow tubular segment.

[0008] The referred document describes the aerosol generating article that can be manufactured efficiently and at high speed, preferably with a satisfactory RTD and low RTD variability from one article to another. However, the referred document does not address the need to cool the aerosols without significantly increasing the ventilation percentage and diluting the aerosol.

[0009] Another patent document WO2021170672A1 titled, “Aerosol-generating article with dual hollow tubular segment” describes an aerosol generating article including a rod of an aerosol generating substrate, and a downstream section at a location downstream of the rod of the aerosol generating substrate. The downstream section includes a support element located immediately downstream of the rod of the aerosol generating substrate. The support elementbeing in longitudinal alignment with the rod and includes a first hollow tubular segment having an internal diameter (DFTS), and an aerosol cooling element positioned immediately downstream of the support element and in longitudinal alignment with the rod and the support element. The aerosol cooling element includes a second hollow tubular segment having an internal diameter (DSTS). The aerosol generating article further includes a ventilation zone at a location along the second hollow tubular segment. The internal diameter (DSTS) of the second hollow tubular segment is greater than the internal diameter (DFTS) of the first hollow tubular segment. A ratio between the internal diameter (DSTS) of the second hollow tubular segment and the internal diameter (DFTS) of the first hollow tubular segment being at least about 1.25. The referred document focuses on the aerosol generating article adapted to achieve at least one of the desirable results such as the aerosol cooling element adapted to lower the temperature of the aerosol, a low-filtration mouthpiece element etc. However, the referred document fails to address the need to cool the aerosol without significantly increasing the ventilation percentage and diluting the aerosol.

[0010] Yet another patent document WO2022074159A1 titled, “Aerosol-generating article with low resistance to draw and improved flavour delivery” describes an aerosol generating article for producing an inhalable aerosol upon heating extends from a mouth end to a distal end. The aerosol generating article includes a rod-shaped aerosol generating element including an aerosol generating substrate, where the aerosol generating substrate includes an aerosol former, and a downstream section at a location downstream end of the aerosol generating element. The downstream section includes a hollow tubular element. A length to diameter ratio of the aerosol generating element is from about 0.5 to about 3.0 An RTD of the downstream section is less than 10 mm H2O.

[0011] The referred documents also describe the aerosol generating article adapted to achieve at least one of the desirable results such as the aerosol generating element adapted to lower the temperature of the aerosol, a low filtration mouthpiece element etc. Further, it would be desirable to provide one such aerosol generating article that can be manufactured efficiently and at high speed, preferably with a satisfactory RTD and low RTD variability from one article to another. However, the referred document fails to address the need to cool the aerosol without significantly increasing the ventilation percentage and diluting the aerosol.

[0012] Thus, the above referred documents are insufficient in addressing the need to cool the aerosol without significantly increasing the ventilation percentage and diluting the aerosol. Further, a limitation of design as per the referred documents is the high pressure drop across the aerosol generating article, especially in the presence of the front plug. Higher RTD iscompensated by increasing ventilation on the bridge section located downstream side of the aerosol generating substrate to reduce the resistance to draw in the referred documents. This leads to dilution of the aerosol due to excessive mixing of ambient air, resulting in a reduced sensorial experience of the user. The referred documents do not describe any way to minimize this effect for the aerosol generating article. In addition, they do not address the impact of ventilation upstream of the aerosol generating substrate.

[0013] Thus, there arises a need for modification in design of the aerosol generating article to address the above said issues.

[0014] There is therefore a need in the art to develop a simple, compact and cost-effective aerosol generating article with a ventilation agreement to reduce pressure drop across the aerosol generating article, as well as minimize the dilution of aerosol quality.OBJECTS OF THE PRESENT DISCLOSURE

[0015] Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as listed herein below.

[0016] It is an object of the present disclosure to provide a simple, compact and cost-effective aerosol generating article with optimal pressure drop across the aerosol generating article.

[0017] It is an object of the present disclosure to provide an aerosol generating article designed to eliminate the need for excessive ventilation on a downstream side of an aerosol generating element, which causes dilution of an aerosol.

[0018] It is an object of the present disclosure to design an aerosol generating article to increase contact time between an ambient air and the generated aerosol, resulting in a cooling effect that improves quality of the aerosol and user experience.

[0019] It is yet another object of the present disclosure to provide an aerosol generating article to improve sensorial quality of the aerosol, offering enhanced user experience.SUMMARY

[0020] Aspects of the present disclosure relate generally to the field of aerosol generating articles. In particular, the present disclosure pertains to an aerosol generating article designed with a unique ventilation arrangement on upstream end of the article to reduce pressure drop across the aerosol generating article. The ventilation arrangement can be defined as row of perforation on wrapping paper, on bridge segment, or on a segment of the article having highly permeable wrapping paper through which ambient air can pass through easily. The ventilation arrangement may include a plurality of perforations (also referred as “ventilation holes”herein), wherein the central axis of each perforation may be inclined at a pre-defined angle with respect to an axis radially normal to the circumference of the article.

[0021] According to an aspect of the present disclosure, the disclosed aerosol generating article (simply referred to as “article” herein) consists of a mouth filter segment, at least one bridge segment that provide zero resistance to draw (RTD) passage to aerosol flow, at least one aerosol generating substrate segment, and an upstream segment. The upstream segment is configured at an upstream end of the aerosol generating article, and coupled to the at least one aerosol generating substrate segment. The article includes a ventilation arrangement that may be provided in one or more segments upstream to the aerosol generating substrate segment or towards the distal end of the aerosol generating substrate segment itself, to facilitate an airflow through the aerosol generating substrate.

[0022] In one or more embodiments, a length of the aerosol generating article may vary from 40 mm to 85 mm. A length of the aerosol generating substrate may vary from 10 mm to 24 mm. An outer diameter of the aerosol generating article may be less than 8.4 mm, preferably less than 7.0 mm. An internal diameter of the bridge segment may vary from 2.1 mm to 7.2 mm. Further, a thickness of a wall of the bridge segment may vary from 50 pm to 2.6 mm. In addition, a length of the upstream segment may vary from 3 mm to 10 mm.

[0023] In one or more embodiments, the upstream segment may be made of one or combination of materials like, a low-density filter material, such as acetate, paper, convoluted paper sheet, nonwoven material crimped sheet including paper, recon, organic materials, silicon and others but not restricted to only these materials.

[0024] In one or more embodiments, the upstream segment may be made from a filter material. The filter material may be selected from silicon, acetate, paper, recon, wood, pulp, cotton linters, plant fibres, paper composites, synthetic polymers, synthetic fibres, gelatine -based materials, metallic substrate, or hybrid substrate or combination thereof.

[0025] In one or more embodiments, the paper may be convoluted, folded, crimped, or embossed.

[0026] In one or more embodiments, the position of the ventilation arrangement on an upstream end of the aerosol generating article may vary from at least 77 mm to 32 mm from a downstream end of the mouth filter segment or in other words at least 1 mm to 8 mm from the upstream end of the aerosol generating article or at least 12 mm to 26 mm from a downstream end of the aerosol generating substrate segment.

[0027] In one or more embodiments, the range of ventilation on the upstream end of the aerosol generating article may vary from 10% to 80%.

[0028] In one or more embodiments, the at least one bridge segment may include a first bridge segment coupling the mouth filter segment to the aerosol generating substrate segment. The first bridge segment may be adapted to refine the airflow and provide additional filtration for the aerosol generated.

[0029] In one or more embodiments, the article may be circumscribed by a wrapping paper.

[0030] In one or more embodiments, the ventilation arrangement may include a plurality of perforations provided on the wrapping paper to facilitate even distribution of the airflow towards the aerosol generating substrate segment.

[0031] In one or more embodiments, the ventilation arrangement may be disposed near an upstream end of the aerosol generating substrate segment to allow maximum airflow to pass through the at least one aerosol generating substrate segment.

[0032] In one or more embodiments, a length of the first bridge segment may be reduced to a pre-defined value, and a second bridge segment may be coupled to the upstream end of the aerosol generating substrate segment of length equal to the pre-defined value.

[0033] In one or more embodiments, the ventilation arrangement may be positioned at the second bridge segment having a hollow cavity to facilitate air intake from upstream of the aerosol generating substrate segment.

[0034] In one or more embodiments, the aerosol generating substrate may be in the form of one or more sheets of homogenized plant material, cut form of plant leaves or a combination thereof.

[0035] In one or more embodiments, the aerosol generating substrate material may be selected from a group consisting of: wood, pulp, cotton linters, plant fibers, paper composites, synthetic polymers, synthetic fibres, gelatin-based materials, metallic substrate, or hybrid substrate.

[0036] In another aspect, an aerosol generating system is disclosed. The aerosol generating system includes an aerosol generating article and an aerosol generating device. The aerosol generating device includes a heating cavity for receiving the aerosol generating article, and a heating element positioned around a periphery of the heating cavity.

[0037] In one or more embodiments, at least one aerosol generating substrate segment of the aerosol generating article may be positioned near at least one heater (simply referred as “heater” herein). The heater may be positioned in the aerosol generating device to heat the aerosol generating substrate uniformly.

[0038] In one or more embodiments, the heater may include one or more of: a periphery heater, a core heater, and a base heater or combination thereof.BRIEF DESCRIPTION OF DRAWINGS

[0039] The accompanying drawings are included to provide a further understanding of the present disclosure, and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure. The diagrams are for illustration only, which thus is not a limitation of the present disclosure.

[0040] FIG. 1A illustrates an exemplary representation of the proposed aerosol generating article having a ventilation arrangement provided in an upstream segment of the aerosol generating article, in accordance with a first embodiment of the present disclosure.

[0041] FIG. IB illustrates an exemplary representation of the proposed aerosol generating article having a ventilation arrangement provided close to an upstream end of an aerosol generating substrate segment of the aerosol generating article, in accordance with a second embodiment of the present disclosure.

[0042] FIG. 1C illustrates an exemplary representation of the proposed aerosol generating article having a ventilation arrangement provided in a second bridge segment, in accordance with a third embodiment of the present disclosure.

[0043] FIG. 2 illustrates an exemplary block diagram representing an aerosol generating system with reduced pressure drop and enhanced user experience, in accordance with an embodiment of the present disclosure.DETAILED DESCRIPTION

[0044] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the present disclosure.

[0045] In the following description, numerous specific details are set forth in order to provide a thorough understanding of embodiments of the present invention. It will be apparent to one skilled in the art that embodiments of the present invention may be practiced without some of these specific details.

[0046] If the specification states a component or feature “may”, “can”, “could”, or “might” be included or have a characteristic, that particular component or feature is not required to be included or have the characteristic.

[0047] As used in the description herein that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.

[0048] The use of “including”, “comprising” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. The terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items. Further, the use of terms “first”, “second”, and “third”, and the like, herein does not denote any order, quantity, or importance, but rather are used to distinguish one element from another.

[0049] Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member can be referred to individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and / or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified thus fulfilling the written description of all groups used in the description herein.

[0050] Exemplary embodiments will now be described more fully hereinafter with reference to the accompanying drawings, in which exemplary embodiments are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. These embodiments are provided so that this disclosure will be thorough and complete and will fully convey the scope of the invention to those of ordinary skilled in the art. Moreover, all statements herein reciting embodiments of the invention, as well as specific examples thereof, are intended to encompass both structural and functional equivalents thereof. Additionally, it is intended that such equivalents include both currently known equivalents as well as equivalents developed in the future (i.e., any elements developed that perform the same function, regardless of structure).

[0051] The present disclosure relates to the field of aerosol generating devices. More particularly, the present disclosure relates to an aerosol generating article designed with a ventilation arrangement to reduce pressure drop across the aerosol generating article. The ventilation arrangement can be defined as row of perforation on wrapping paper, on bridge segment, or on a segment of the article having highly permeable wrapping paper through which ambient air can pass through easily. The ventilation arrangement can include a plurality of perforations (also referred as “ventilation holes” herein), where a central axis of eachperforation can be inclined at a pre-defined angle with respect to an axis radially normal to the circumference of the aerosol generating article.

[0052] Existing aerosol generating articles face several drawbacks, particularly related to the high pressure drop across an aerosol generating substrate segment, especially in the presence of an upstream segment. To compensate for this, prior art designs often increase ventilation on a downstream end of the aerosol generating substrate segment, which reduces the resistance to draw but leads to excessive mixing of ambient air, causing dilution of the aerosol. This dilution results in a reduced sensorial experience for the user, as the aerosol becomes less dense and loses its intended flavor and cooling effect. Additionally, prior art fails to address the impact of ventilation upstream of the aerosol generating article, and the designs are often constrained by limited space for optimizing airflow, which further aggravates these issues without offering effective solutions for improving aerosol quality and user satisfaction.

[0053] To address the aforesaid issue, the proposed aerosol generating article has been designed with a novel approach that reduces a pressure drop across the aerosol generating article by strategically introducing a ventilation arrangement upstream of an aerosol generating substrate segment. This design modification alleviates the need for excessive downstream ventilation, thus minimizing dilution of the aerosol and preserving the desired aerosol characteristics such as density and cooling effect. By optimizing the placement of ventilation around the upstream segment or on bridge segment or near the upstream end of the aerosol generating substrate, the proposed aerosol generating article enhances the overall user experience by providing a more efficient and effective airflow, leading to a denser aerosol with improved sensorial quality.

[0054] As illustrated, in an embodiment, referring to FIG. 1A, the proposed aerosol generating article 100 includes a main body 101 consists of a mouth filter segment 102, at least one bridge segment , at least one aerosol generating substrate segment 106 (also simply referred to as “aerosol generating substrate segment 106” or “substrate segment 106” hereinafter), and an upstream segment 108. The mouth filter segment 102 is configured at a downstream end 100-2 of the aerosol generating article 100 to filter an aerosol before the aerosol is inhaled by a user. The at least one bridge segment can include a first bridge segment 104 designed to allow mixing of air with an aerosol, cooling of the aerosol, refine the airflow and provide additional filtration. The first bridge segment 104 further consists of ventilation to cool the aerosol and reduce the pressure drop in the aerosol generating article 100. Further, the aerosol generating substrate segment 106 is configured to produce the aerosol. The aerosol generating substrate segment 106 can optionally include a heating segment (not shown in figure) configured to heat anaerosol generating substrate internally. In addition, the upstream segment 108 includes a ventilation arrangement 110 provided to facilitate an airflow through the upstream segment 108 towards the aerosol generating substrate segment 106.

[0055] In an embodiment, the ventilation arrangement 110 can include a plurality of perforations provided on a wrapping paper. The aerosol generating article 100 can be circumscribed by this pre -perforated or highly permeable wrapping paper. The ventilation arrangement 110 can also include the plurality of perforations (also referred as “ventilation holes” herein) such that a central axis of each perforation can be inclined at a pre-defined angle with respect to an axis radially normal to a circumference of the aerosol generating article 100.

[0056] In one or more embodiments, a length of the aerosol generating article 100 can vary from 40 mm to 85 mm. A length of the aerosol generating substrate segment 106 can vary from 10 mm to 24 mm, without any limitations. An outer diameter of the aerosol generating article 100 can be less than, but not limited to, 8.4 mm, preferably less than 7.0 mm. An internal diameter of the bridge segment can vary from 2.1 mm to 7.2 mm, without any limitations. A thickness of a wall of the bridge segment can vary from, but not limited to, 50 pm to 2.6 mm. In addition, a length of the upstream segment 108 can vary from, but not limited to, 3 mm to 10 mm.

[0057] In one or more embodiments, the upstream segment 108 can be made of one or combination of materials like, a low-density filter material, such as acetate, paper, convoluted paper sheet, non-woven material crimped sheet including paper, recon, organic materials, silicon and others but not restricted to only these materials. In one or more embodiments, the upstream segment 108 can be made from a filter material. The filter material can be selected from, but not limited to, silicon, acetate, paper, recon, wood, pulp, cotton linters, plant fibres, paper composites, synthetic polymers, synthetic fibres, gelatine-based materials, metallic substrate, or hybrid substrate or combination thereof. In one or more embodiments, the paper is convoluted, folded, crimped, or embossed.

[0058] In one or more embodiments, the position of the ventilation arrangement 110 on an upstream end 100-1 of the aerosol generating article 100 can vary from at least 77 mm to 32 mm from a downstream end of the mouth filter segment 102 or in other words at least 1 mm to 8 mm from the upstream end 100-1 of the aerosol generating article 100 or at least 12 mm to 26 mm from a downstream end of the aerosol generating substrate segment 106.

[0059] In one or more embodiments, the range of ventilation on the upstream end 100-1 of the aerosol generating article 100 may vary from 10% to 80%. More preferably below 60%.

[0060] In an embodiment, the aerosol generating substrate segment 106 can be placed near at least one heater 204 (simply referred to as “heater 204” herein) of an aerosol generating device 202. The heater 204 can be selected from but not limited to a core heater, a periphery heater or combination thereof.

[0061] In an embodiment, the aerosol generating substrate can be in the form of one or more sheets of homogenized plant material. These sheets serve as the core component responsible for generating the aerosol when heated. The use of homogenized plant material allows for a uniform composition that ensures consistent aerosol production, as well as an efficient transfer of heat throughout the substrate. The sheets of homogenized plant material can be produced through different manufacturing processes, depending on the desired properties of the substrate. In one embodiment, the sheets may be produced using a casting process, where a slurry of homogenized plant material is poured onto a surface and allowed to dry, forming a thin, uniform sheet. The casting process allows for precise control over the thickness, texture, and uniformity of the sheets, making it ideal for creating substrates with specific performance characteristics, such as optimal porosity for airflow and even distribution of heat. Alternatively, the one or more sheets of homogenized plant material can be produced using a paper-making process, where plant fibers, often combined with binding agents, are processed into a slurry and formed into sheets through a series of mechanical steps, including pressing and drying. This method can be used for producing thin, flexible, and strong sheets that can efficiently support aerosol generation.

[0062] The aerosol generating substrate can be made of materials selected from but not limited to cellulose-based materials such as wood pulp, cotton linters, plant fibers, paper composites, synthetic polymers, synthetic fibers, gelatin-based materials, metallic substrate, hybrid substrate, and the like.

[0063] In a second embodiment and referring to FIG. IB, the ventilation arrangement 110 can be configured near an upstream end 106-1 of aerosol generating substrate segment 106 of the aerosol generating article 100 to allow maximum airflow to pass through the aerosol generating substrate segment 106. The ventilation arrangement 110 can be configured in the aerosol generating substrate segment 106. The introduction of the ventilation arrangement 110 near the upstream end 106-1 of the aerosol generating substrate segment 106 can help in reducing pressure drop and enhance the user experience by facilitating easier airflow through the aerosol generating substrate segment 106.

[0064] In an embodiment, the aerosol generating substrate segment 106 is of cylindrical shape and can include the aerosol generating substrate circumscribed by the wrapping paper. Thecylindrical shape of the aerosol generating substrate segment 106 can help in optimizing airflow and facilitate uniform aerosol generation. The heat can be applied to an entire circumference of the cylindrical aerosol generating substrate segment 106, leading to consistent aerosol production. This shape also promotes a more controlled and efficient aerosolization process as the airflow can circulate evenly around the aerosol generating substrate segment 106. Further, the wrapping paper that circumscribes the aerosol generating substrate can be crucial for holding the aerosol generating substrate in place, preventing it from unraveling or disintegrating during use. This paper also acts as a protective layer, ensuring that the aerosol generating substrate maintains its integrity and performance while being used in the aerosol generating device.

[0065] In an embodiment, the wrapping paper can be designed with specific porosity or permeability to control airflow around the aerosol generating substrate. In some embodiments, the wrapping paper can feature micro-perforations or a breathable / porous structure that can allow the ambient air to pass through while maintaining a sufficient barrier to retain the aerosol within the aerosol generating substrate's area. This controlled airflow helps regulate the temperature of the aerosol and the user’s inhalation experience. Additionally, by optimizing the placement and design of the wrapping paper, the need for excess ventilation downstream can be reduced.

[0066] In an embodiment, the wrapping paper can be made of materials such as cellulose-based papers, perforated films, coated papers, and the like, without any limitations whatsoever.

[0067] In an embodiment, the bridge segment 104 is a segment of aerosol generating article 100 that provide zero resistance to draw (RTD) passage, for the flow of aerosol or air in the article 100. The bridge segment 104 can be made of a material selected from, but not limited to, organic or inorganic materials or combination thereof, cellulose base matric, acetate, cellulose-based paper, reconstituted plant-based sheet, non-woven fabric, polymeric film, or any combination thereof, optionally incorporating additives such as plasticizers, bum modifiers, or porosity-controlling agents to achieve desired functional characteristics.

[0068] In one or more embodiments, the upstream segment 108 can be made from braided construct of strands, in which multiple strings are intertwined. The braided construct may provide density variation of fiber material from the center to a peripheral region of the upstream segment 108. The braided construct may be wrapped with a sheet material to improve adhesion of the braided construct with rest of the aerosol generating article 100.

[0069] In one or more embodiments, the upstream segment 108 may be constructed from the natural fibers selected from jute, banana leaf fiber, flax, kenaf, ramie, industrial hemp, vinefibers, and coconut fiber. Further, the upstream segment 108 may be coated with heat-resistant coating selected from Polytetrafluoroethylene (PTFE) coating, neoprene-based coating, phenolic based coating, silicone-based coating, ceramic-based coating, and refractory coating.

[0070] Referring to FIG. 1C and according to a third embodiment of the present disclosure, the aerosol generating article 100 can include an additional bridge segment, which can be referred as a second bridge segment 112. Further a length of the first bridge segment 104 can be reduced to configure the second bridge segment 112 at the upstream end 106-1 of the aerosol generating substrate segment 106. The ventilation arrangement 110 can be configured to facilitate an air intake from the upstream of the aerosol generating substrate segment 106. The first and second bridge segments 104, 112 can have a hollow cavity to facilitate even distribution of the airflow towards the aerosol generating substrate segment 106.

[0071] In another embodiment and referring to FIG. 2, the present disclosure pertains to an aerosol generating system 200 (referred simply as “system 200” hereinafter) with reduced pressure drop and enhanced user experience. The system 200 includes an aerosol generating article 100, and an aerosol generating device 202 (referred simply as “device 202” hereinafter) includes a heating cavity for receiving the aerosol generating article 100, and a heating element positioned in the heating cavity. The aerosol generating device 202 can include a power source 206, and a controller 208 operatively coupled to the power source 206. The aerosol generating substrate segment 106 can be positioned near at least one heater 204 (simply referred as “heater 204” herein) of the aerosol generating device 202 to heat the aerosol generating uniformly. The heater 204 can be any of: a peripheral heater, a base heater, a core heater, or combination thereof, without any limitations. In a preferred embodiment, the heater 204 can be the periphery heater disposed along a periphery of the heater cavity.

[0072] Upon actuation of the device 202, the controller 208 can actuate the power source 206 to transmit power to the heater 204, and other components of the aerosol generating device 202. On receiving the power, the heater 204 can initiate heating the aerosol generating article 100, which is in the form of rod, surrounded with the heater 204. The aerosol generated by heating of an aerosol generating substrate, can be inhaled by the user through a mouth filter segment 102 configured at a downstream end 100-2 of the article 100.

[0073] In an embodiment, the aerosol generating substrate can be configured in an aerosol generating substrate segment 106 of the aerosol generating article 100. In an embodiment, a ventilation arrangement 110 can be disposed at an upstream end 106- 1 of the aerosol generating substrate segment 106 to facilitate airflow within the article 100. Further, the aerosol generating article 100 can include an upstream segment 108 configured adjacent to the aerosol generatingsubstrate segment 106. In another embodiment, the ventilation arrangement 110 can be configured at an upstream end 100-1 of the aerosol generating article 100.

[0074] In an embodiment, the aerosol generating article 100 can be circumscribed by a wrapping paper. The ventilation arrangement 110 can include a plurality of perforations provided on the wrapping paper to facilitate even distribution of the airflow towards the aerosol generating substrate segment 106.

[0075] In an embodiment, the power source 206 can be a battery, including, without limitations, a rechargeable lithium-ion battery, a lithium polymer battery, Nickel-metal Hydride (NiMH) battery, and the like. The battery provides the electric current required to heatup the heating element of the heater 204, and aerosolize the aerosol generating substrate. In another embodiment, the heater 204 can be connected to the power source 206. Upon actuation of the aerosol generating device 202, the power source 206 can transmit the electric current through the heating element, which results in heating-up of the heating element.

[0076] In an embodiment, the controller 208 may include one or more processors (interchangeably referred to as processor, hereinafter). The processor may be implemented as one or more microprocessors, microcomputers, microcontrollers, edge or fog microcontrollers, digital signal processors, central processing units, logic circuitries, and / or any devices that process data based on operational instructions. Among other capabilities, the processor may be configured to fetch and execute computer-readable instructions stored in a memory of the controller 208. The memory may be configured to store one or more computer-readable instructions or routines in a non-transitory computer readable storage medium, which may be fetched and executed to actuate the heater 204, upon detection of airflow by at least inhalation sensor, thereby generating the aerosol for inhalation by the user.

[0077] In an embodiment, the memory may comprise any non-transitory storage device including, for example, volatile memory such as Random Access Memory (RAM), or nonvolatile memory such as Erasable Programmable Read-Only Memory (EPROM), flash memory, and the like.

[0078] As can be appreciated, the proposed aerosol generating article 100 introduces a ventilation arrangement 110 having a plurality of perforations at an upstream end 106-1 of an aerosol generating substrate segment 106 helps in reducing the pressure drop, making it easier for air to flow through an aerosol generating substrate, thus enhancing the overall airflow dynamics. By optimizing the airflow, the proposed aerosol generating article 100 can facilitate smoother, more consistent inhalation, improving the user experience, and ensuring that the aerosol can be generated efficiently without excessive Resistance to Draw (RTD).

[0079] While the foregoing describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The invention is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.ADVANTAGES OF THE INVENTION

[0080] The present invention provides a simple, compact and cost-effective aerosol generating article to reduce pressure drop across the aerosol generating article.

[0081] The present invention provides an aerosol generating article designed to eliminate the need for excessive ventilation on a downstream end of an aerosol generating substrate segment, which causes dilution of an aerosol.

[0082] The present invention provides an aerosol generating article designed to increase contact time between an ambient air and the generated aerosol, resulting in a cooling effect that improves quality of the aerosol and user experience.

[0083] The present invention provides an aerosol generating article to improve sensorial quality of the aerosol, offering enhanced user experience.

Claims

We Claim:

1. An aerosol generating article (100) comprising:a mouth filter segment (102) positioned at the downstream end (100-2) of the aerosol generating article (100);at least one bridge segment that provide zero resistance to draw (RTD) passage to aerosol flow;at least one aerosol generating substrate segment (106) coupled to the at least one bridge segment and comprises an aerosol generating substrate; andan upstream end (100-1) of the aerosol generating article (100), coupled to the at least one aerosol generating substrate segment (106), wherein the upstream end (100- 1) comprises a ventilation arrangement (110) to facilitate an airflow from the upstream end (100-1) through the aerosol generating substrate.

2. The aerosol generating article (100) as claimed in claim 1, wherein the upstream end (100-1) of the aerosol generating article (100) consists of one or more segments positioned upstream to the at least one aerosol generating substrate segment (106).

3. The aerosol generating article (100) as claimed in claim 1, wherein the ventilation arrangement ( 110) is disposed near an upstream segment ( 108) of the aerosol generating article (100) to allow maximum airflow to pass through the at least one aerosol generating substrate segment (106).

4. The aerosol generating article (100) as claimed in claim 1, wherein the ventilation arrangement (110) is provided at a distance ranging from 12 mm to 26 mm from a downstream end of the at least one aerosol generating substrate segment (106).

5. The aerosol generating article (100) as claimed in claim 1, wherein the ventilation is maintained below 60% on the upstream end (100-1) of the aerosol generating article (100).

6. The aerosol generating article (100) as claimed in claim 1, is circumscribed by a wrapping paper.

7. The aerosol generating article (100) as claimed in claim 6, wherein the ventilation arrangement (110) comprises a plurality of perforations provided on the wrapping paper to facilitate even distribution of the airflow towards the at least one aerosol generating substrate segment (106).

8. The aerosol generating article (100) as claimed in claim 1, wherein the ventilation arrangement (110) is disposed near an upstream end (106-1) of the at least one aerosolgenerating substrate segment (106) to allow maximum airflow to pass through the at least one aerosol generating substrate segment (106).

9. The aerosol generating article (100) as claimed in claim 1, wherein the ventilation arrangement (110) is disposed near a downstream end of upstream segment (108) to allow maximum airflow to pass through the at least one aerosol generating substrate segment (106).

10. The aerosol generating article (100) as claimed in claim 1, wherein the at least one bridge segment comprises a first bridge segment (104) coupling the mouth filter segment (102) to the at least one aerosol generating substrate segment (106), wherein the first bridge segment (104) is adapted to refine the airflow and provide additional filtration for the aerosol generated.

11. The aerosol generating article (100) as claimed in claim 10, wherein the first bridge segment (104) consists of ventilation to cool the aerosol and reduce the pressure drop in the aerosol generating article (100).

12. The aerosol generating article ( 100) as claimed in claim 10, wherein a length of the first bridge segment (104) is reduced to a pre-defined value, and a second bridge segment (112) is coupled to the upstream end (106-1) of the at least one aerosol generating substrate segment (106) of length equal to the pre-defined value.

13. The aerosol generating article (100) as claimed in claims 1 and 12, wherein the ventilation arrangement (110) is positioned at the second bridge segment (112) having a hollow cavity to facilitate air intake from upstream of the at least one aerosol generating substrate segment (106).

14. The aerosol generating article (100) as claimed in claim 1, wherein the at least one aerosol generating substrate segment (106) is in the form of one or more sheets of homogenized plant material, cut form of plant leaves or a combination thereof.

15. The aerosol generating article (100) as claimed in claim 1, wherein the upstream segment (108) is made from a filter material.

16. The aerosol generating article (100) as claimed in claim 15, wherein the filter material is selected from at least one of: silicon, acetate, paper, recon, wood, pulp, cotton linters, plant fibers, paper composites, synthetic polymers, synthetic fibres, gelatine-based materials, metallic substrate, or hybrid substrate or combination thereof.

17. The aerosol generating article (100) as claimed in claim 16, wherein the paper is convoluted, folded, crimped, or embossed.

18. An aerosol generating system (200) comprising:an aerosol generating article (100) as claimed in claim 1; andan aerosol generating device (202) comprises a heating cavity for receiving the aerosol generating article (100); and at least one heater (204) positioned in and around the heating cavity.

19. The aerosol generating system (200) as claimed in claim 18, wherein at least one aerosol generating substrate segment (106) of the aerosol generating article (100) is positioned near at least one heater (204), to heat the aerosol generating substrate segment (106) uniformly for better user experience.

20. The aerosol generating system (200) as claimed in claim 18, wherein the at least one heater (204) comprises of: a periphery heater, a core heater, a base heater or combination thereof.

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