Aerosol-generating substrate with improved construction

Abstract

The present invention relates to an aerosol-generating article (100) for producing an inhalable aerosol upon heating. The aerosol-generating article comprises: a rod (12) of aerosol-generating substrate comprising an aerosol former; an upstream element (10) provided upstream of the rod (12) and abutting an upstream end of the rod (12); a mouthpiece segment (14) arranged downstream of the rod (12) and in longitudinal alignment with the rod (12); a wrapper (16) circumscribing the rod (12) and the mouthpiece segment (14), the wrapper (16) forming a peripheral wall of a hollow tubular segment (24) defining a cavity (26) in longitudinal alignment with the rod (12) and the mouthpiece segment (14). The cavity (26) extends longitudinally all the way to the mouthpiece segment (14) and radially all the way to the wrapper (16). A length of the cavity (26) is at least 15 millimetres.

Description

[0001] P / 90834.W001

[0002] - 1 - AEROSOL-GENERATING SUBSTRATE WITH IMPROVED CONSTRUCTION

[0003] The present invention relates to an aerosol-generating article comprising an aerosolgenerating substrate and adapted to produce an inhalable aerosol upon heating.

[0004] Aerosol-generating articles in which an aerosol-generating substrate, such as a tobaccocontaining substrate, is heated rather than combusted, are known in the art. Typically, in such heated smoking articles an aerosol is generated by the transfer of heat from a heat source to a physically separate aerosol-generating substrate or material, which may be located in contact with, within, around, or downstream of the heat source. During use of the aerosol-generating article, volatile compounds are released from the aerosol-generating substrate by heat transfer from the heat source and are entrained in air drawn through the aerosol-generating article. As the released compounds cool, they condense to form an aerosol.

[0005] A number of prior art documents disclose aerosol-generating devices for consuming aerosol-generating articles. Such devices include, for example, electrically heated aerosolgenerating devices in which an aerosol is generated by the transfer of heat from one or more electrical heater elements of the aerosol-generating device to the aerosol-generating substrate of a heated aerosol-generating article. For example, electrically heated aerosol-generating devices have been proposed that comprise an internal heater blade which is adapted to be inserted into the aerosol-generating substrate. Use of an aerosol-generating article in combination with an external heating system is also known. For example, WO 2020 / 115151 describes the provision of one or more heating elements arranged around the periphery of the aerosol-generating article when the aerosol-generating article is received in a cavity of the aerosol-generating device. As an alternative, inductively heatable aerosol-generating articles comprising an aerosol-generating substrate and a susceptor arranged within the aerosol-generating substrate have been proposed by WO 2015 / 176898.

[0006] Aerosol-generating articles in which a tobacco-containing substrate is heated rather than combusted present a number of challenges that were not encountered with conventional smoking articles.

[0007] First of all, tobacco-containing substrates are typically heated to significantly lower temperatures compared with the temperatures reached by the combustion front in a conventional cigarette. This may have an impact on nicotine release from the tobacco-containing substrate and nicotine delivery to the consumer. At the same time, if the heating temperature is increased in an attempt to boost nicotine delivery, then the aerosol generated typically needs to be cooled to a greater extent and more rapidly before it reaches the consumer. However, technical solutions that were commonly used for cooling the mainstream smoke in conventional smoking articles, such as the provision of a high filtration efficiency segment at the mouth end of a cigarette, may have undesirable effects in an aerosol-generating article wherein a tobacco-containing substrateis heated rather than combusted, as they may reduce nicotine delivery. Accordingly, it is generally desirable to provide novel aerosol-generating articles that can consistently ensure a satisfactory aerosol delivery to the consumer.

[0008] Secondly, a need is generally felt for aerosol-generating articles that are easy to use, have improved practicality, and can be manufactured requiring only minor modifications to existing equipment and processes.

[0009] For example, it would be desirable to provide an aerosol-generating article that can be easily manufactured by assembling a reduced number of components compared with existing aerosol-generating articles. Further, it would be desirable to provide an aerosol-generating article having properties that can be finely controlled with consistency despite possible oscillations in the size of individual components - which may, for example, be caused by variations in environmental factors (humidity level, overall weather conditions) - modifications of the manufacturing apparatus, and so forth.

[0010] Therefore, it would be desirable to provide a new and improved aerosol-generating article adapted to achieve at least one of the desirable results described above.

[0011] According to the present disclosure, there is provided an aerosol-generating article for producing an inhalable aerosol upon heating.

[0012] The aerosol-generating article may comprise a rod of aerosol-generating substrate comprising an aerosol former.

[0013] The aerosol-generating article may comprise a rod of aerosol-generating substrate comprising an aerosol former and an upstream element provided upstream of the rod, in longitudinal alignment with the rod and abutting an upstream end of the rod.

[0014] The aerosol-generating article may comprise a rod of aerosol-generating substrate comprising an aerosol former and a mouthpiece segment arranged downstream of the rod and in longitudinal alignment with the rod. The aerosol-generating article may further comprise a wrapper circumscribing the rod and the mouthpiece segment, the wrapper forming a peripheral wall of a hollow tubular segment defining a cavity in longitudinal alignment with the rod and the mouthpiece segment.

[0015] The aerosol-generating article may comprise a rod of aerosol-generating substrate comprising an aerosol former; an upstream element provided upstream of the rod, in longitudinal alignment with the rod and abutting an upstream end of the rod; and a mouthpiece segment arranged downstream of the rod and in longitudinal alignment with the rod. The aerosolgenerating article may further comprise a wrapper circumscribing the rod and the mouthpiece segment, the wrapper forming a peripheral wall of a hollow tubular segment defining a cavity in longitudinal alignment with the rod and the mouthpiece segment, the cavity arranged between the rod and the mouthpiece segment.The cavity may extend longitudinally all the way to the mouthpiece segment. The cavity may extend radially all the way to the wrapper. A length of the cavity may be at least 15 millimetres.

[0016] An outer surface of the wrapper may form at least part of an outer surface of the aerosolgenerating article. That is, over at least part of the length of the aerosol-generating article, an outer surface of the wrapper is exposed to the outer environment, as the aerosol-generating article does not comprise any further component circumscribing the wrapper over said part of the length of the aerosol-generating article.

[0017] In particular, an outer surface of the wrapper may form an outer surface of the aerosolgenerating article over the entire length of the cavity. That is, over at least the length of the cavity, an outer surface of the wrapper is exposed to the outer environment, as the aerosol-generating article does not comprise any further component circumscribing the wrapper over said the entire length of the cavity.

[0018] An outer surface of the wrapper may form an outer surface of the aerosol-generating article over the entire length of the aerosol-generating article. That is, over the entire length of the aerosol-generating article, an outer surface of the wrapper is exposed to the outer environment, as the aerosol-generating article does not comprise any further component circumscribing the wrapper at any location along the length of the wrapper.

[0019] According to a first example, an aerosol-generating article for producing an inhalable aerosol upon heating may comprise: a rod of aerosol-generating substrate comprising an aerosol former; a mouthpiece segment arranged downstream of the rod and in longitudinal alignment with the rod; and a wrapper circumscribing the rod and the mouthpiece segment, the wrapper forming a peripheral wall of a hollow tubular segment defining a cavity in longitudinal alignment with the rod and the mouthpiece segment, wherein an outer surface of the wrapper forms at least part of an outer surface of the aerosol-generating article.

[0020] According to a second example, an aerosol-generating article for producing an inhalable aerosol upon heating may comprise: a rod of aerosol-generating substrate comprising an aerosol former; a mouthpiece segment arranged downstream of the rod and in longitudinal alignment with the rod; and a wrapper circumscribing the rod and the mouthpiece segment, the wrapper forming a peripheral wall of a hollow tubular segment defining a cavity in longitudinal alignment with the rod and the mouthpiece segment, wherein the cavity extends longitudinally all the way to the mouthpiece segment and radially all the way to the wrapper and an outer surface of the wrapper forms at least part of an outer surface of the aerosol-generating article.

[0021] According to a third example, an aerosol-generating article for producing an inhalable aerosol upon heating may comprise: a rod of aerosol-generating substrate comprising an aerosol former; a mouthpiece segment arranged downstream of the rod and in longitudinal alignment with the rod; and a wrapper circumscribing the rod and the mouthpiece segment, the wrapper forminga peripheral wall of a hollow tubular segment defining a cavity in longitudinal alignment with the rod and the mouthpiece segment, wherein an outer surface of the wrapper forms an outer surface of the aerosol-generating article over the entire length of the cavity.

[0022] According to a fourth example, an aerosol-generating article for producing an inhalable aerosol upon heating may comprise: a rod of aerosol-generating substrate comprising an aerosol former; a mouthpiece segment arranged downstream of the rod and in longitudinal alignment with the rod; and a wrapper circumscribing the rod and the mouthpiece segment, the wrapper forming a peripheral wall of a hollow tubular segment defining a cavity in longitudinal alignment with the rod and the mouthpiece segment, wherein the cavity extends longitudinally all the way to the mouthpiece segment and radially all the way to the wrapper and wherein an outer surface of the wrapper forms an outer surface of the aerosol-generating article over the entire length of the cavity.

[0023] According to a fifth example, an aerosol-generating article for producing an inhalable aerosol upon heating may comprise: a rod of aerosol-generating substrate comprising an aerosol former; a mouthpiece segment arranged downstream of the rod and in longitudinal alignment with the rod; and a wrapper circumscribing the rod and the mouthpiece segment, the wrapper forming a peripheral wall of a hollow tubular segment defining a cavity in longitudinal alignment with the rod and the mouthpiece segment, wherein an outer surface of the wrapper forms an outer surface of the aerosol-generating article over the entire length of the aerosol-generating article.

[0024] According to a sixth example, an aerosol-generating article for producing an inhalable aerosol upon heating may comprise: a rod of aerosol-generating substrate comprising an aerosol former; a mouthpiece segment arranged downstream of the rod and in longitudinal alignment with the rod; and a wrapper circumscribing the rod and the mouthpiece segment, the wrapper forming a peripheral wall of a hollow tubular segment defining a cavity in longitudinal alignment with the rod and the mouthpiece segment, wherein the cavity extends longitudinally all the way to the mouthpiece segment and radially all the way to the wrapper and wherein an outer surface of the wrapper forms an outer surface of the aerosol-generating article over the entire length of the aerosol-generating article.

[0025] According to a seventh example, an aerosol-generating article for producing an inhalable aerosol upon heating may comprise: a rod of aerosol-generating substrate comprising an aerosol former; an upstream element provided upstream of the rod, in longitudinal alignment with the rod and abutting an upstream end of the rod; a mouthpiece segment arranged downstream of the rod and in longitudinal alignment with the rod; and a wrapper circumscribing the rod and the mouthpiece segment, the wrapper forming a peripheral wall of a hollow tubular segment defining a cavity in longitudinal alignment with the rod and the mouthpiece segment, wherein an outer surface of the wrapper forms at least part of an outer surface of the aerosol-generating article.According to a eighth example, an aerosol-generating article for producing an inhalable aerosol upon heating may comprise: a rod of aerosol-generating substrate comprising an aerosol former; an upstream element provided upstream of the rod, in longitudinal alignment with the rod and abutting an upstream end of the rod; a mouthpiece segment arranged downstream of the rod and in longitudinal alignment with the rod; and a wrapper circumscribing the rod, the upstream element and the mouthpiece segment, the wrapper forming a peripheral wall of a hollow tubular segment defining a cavity in longitudinal alignment with the rod and the mouthpiece segment, wherein the cavity extends longitudinally all the way to the mouthpiece segment and radially all the way to the wrapper and an outer surface of the wrapper forms at least part of an outer surface of the aerosol-generating article.

[0026] According to a ninth example, an aerosol-generating article for producing an inhalable aerosol upon heating may comprise: a rod of aerosol-generating substrate comprising an aerosol former; an upstream element provided upstream of the rod, in longitudinal alignment with the rod and abutting an upstream end of the rod; a mouthpiece segment arranged downstream of the rod and in longitudinal alignment with the rod; and a wrapper circumscribing the rod, the upstream element and the mouthpiece segment, the wrapper forming a peripheral wall of a hollow tubular segment defining a cavity in longitudinal alignment with the rod and the mouthpiece segment, wherein an outer surface of the wrapper forms an outer surface of the aerosol-generating article over the entire length of the cavity.

[0027] According to a tenth example, an aerosol-generating article for producing an inhalable aerosol upon heating may comprise: a rod of aerosol-generating substrate comprising an aerosol former; an upstream element provided upstream of the rod, in longitudinal alignment with the rod and abutting an upstream end of the rod; a mouthpiece segment arranged downstream of the rod and in longitudinal alignment with the rod; and a wrapper circumscribing the rod, the upstream element and the mouthpiece segment, the wrapper forming a peripheral wall of a hollow tubular segment defining a cavity in longitudinal alignment with the rod and the mouthpiece segment, wherein the cavity extends longitudinally all the way to the mouthpiece segment and radially all the way to the wrapper and wherein an outer surface of the wrapper forms an outer surface of the aerosol-generating article over the entire length of the cavity.

[0028] According to a eleventh example, an aerosol-generating article for producing an inhalable aerosol upon heating may comprise: a rod of aerosol-generating substrate comprising an aerosol former; an upstream element provided upstream of the rod, in longitudinal alignment with the rod and abutting an upstream end of the rod; a mouthpiece segment arranged downstream of the rod and in longitudinal alignment with the rod; and a wrapper circumscribing the rod, the upstream element and the mouthpiece segment, the wrapper forming a peripheral wall of a hollow tubular segment defining a cavity in longitudinal alignment with the rod and the mouthpiece segment,wherein an outer surface of the wrapper forms an outer surface of the aerosol-generating article over the entire length of the aerosol-generating article.

[0029] According to a twelfth example, an aerosol-generating article for producing an inhalable aerosol upon heating may comprise: a rod of aerosol-generating substrate comprising an aerosol former; an upstream element provided upstream of the rod, in longitudinal alignment with the rod and abutting an upstream end of the rod; a mouthpiece segment arranged downstream of the rod and in longitudinal alignment with the rod; and a wrapper circumscribing the rod, the upstream element and the mouthpiece segment, the wrapper forming a peripheral wall of a hollow tubular segment defining a cavity in longitudinal alignment with the rod and the mouthpiece segment, wherein the cavity extends longitudinally all the way to the mouthpiece segment and radially all the way to the wrapper and wherein an outer surface of the wrapper forms an outer surface of the aerosol-generating article over the entire length of the aerosol-generating article.

[0030] According to an aspect of the present invention, there is provided an aerosol-generating article for producing an inhalable aerosol upon heating. The aerosol-generating article comprises: a rod of aerosol-generating substrate comprising an aerosol former; an upstream element provided upstream of the rod, in longitudinal alignment with the rod and abutting an upstream end of the rod; a mouthpiece segment arranged downstream of the rod and in longitudinal alignment with the rod; and a wrapper circumscribing the rod and the mouthpiece segment. The wrapper forms a peripheral wall of a hollow tubular segment defining a cavity in longitudinal alignment with the rod and the mouthpiece segment. The cavity is arranged between the rod and the mouthpiece segment. The cavity extends longitudinally all the way to the mouthpiece segment and radially all the way to the wrapper.

[0031] According to a particularly preferred embodiment of an aspect of the present invention, there is provided an aerosol-generating article for producing an inhalable aerosol upon heating. The aerosol-generating article comprises: a rod of aerosol-generating substrate comprising an aerosol former; an upstream element provided upstream of the rod, in longitudinal alignment with the rod and abutting an upstream end of the rod; a mouthpiece segment arranged downstream of the rod and in longitudinal alignment with the rod; and a wrapper circumscribing the rod and the mouthpiece segment. The wrapper forms a peripheral wall of a hollow tubular segment defining a cavity in longitudinal alignment with the rod and the mouthpiece segment. The cavity is arranged between the rod and the mouthpiece segment. The cavity extends longitudinally all the way to the mouthpiece segment and radially all the way to the wrapper. A length of the cavity is at least 15 millimetres.

[0032] The present invention further relates to an aerosol-generating system for producing an inhalable aerosol, the aerosol-generating system comprising: an aerosol-generating article according to the first aspect of the present invention, and an aerosol-generating device comprisinga heating arrangement configured to heat at least a portion of the aerosol-generating substrate to generate an aerosol.

[0033] As used herein, the term “aerosol-generating substrate” refers to a substrate capable of releasing upon heating volatile compounds, which can condense to form an aerosol.

[0034] As used herein, the term “aerosol” denotes a dispersion of solid particles, or liquid droplets, or a combination of solid particles and liquid droplets, in a gas. The aerosol may be visible or invisible. The aerosol may include vapours of substances that are ordinarily liquid or solid at room temperature as well as solid particles, or liquid droplets, or a combination of solid particles and liquid droplets.

[0035] As used herein, the term “aerosol-generating article” refers to an aerosol-generating article for producing an aerosol comprising an aerosol-generating substrate that is intended to be heated rather than combusted in order to release volatile compounds that can form an aerosol.

[0036] As used herein, the term “aerosol-generating device” denotes a device that interacts with an aerosol-generating substrate to generate an aerosol. In some examples, an aerosolgenerating device heats the aerosol-generating substrate to facilitate release of volatile compounds from the aerosol-generating substrate.

[0037] As used herein, the term “aerosol-generating system” refers to the combination of an aerosol-generating device and an aerosol-generating substrate or article.

[0038] As used herein, a content of a component of the aerosol-generating substrate on a “dry weight basis” refers to the weight of a particular non-water component relative to the sum of the weights of all non-water components in a mixture, expressed as a percentage. A mass ratio of two or more components of an aerosol-generating substrate on a “dry weight basis” refers to a ratio of the weight of a particular non-water component relative to another particular non-water component.

[0039] As described briefly above, in aerosol-generating articles in accordance with the present invention, a wrapper circumscribes both the rod of aerosol-generating substrate and the mouthpiece segment and, in so doing, the wrapper also advantageously defines a peripheral wall of a tubular segment extending between the rod of aerosol-generating substrate and the mouthpiece segment. Accordingly, an internal cavity of the aerosol-generating article is defined between the rod of aerosol-generating substrate and the mouthpiece segment. Said cavity extends all the way to an upstream end of the mouthpiece segment and is delimited in the radial direction by the wrapper itself. In other words, the inner surface of the wrapper forms the inner surface of the hollow tubular segment delimiting the cavity. As a result, during use, said inner surface is directly exposed to the aerosol flowing through the aerosol-generating article.

[0040] As a result, compared with certain existing aerosol-generating articles comprising an internal cavity downstream of the rod of aerosol-generating substrate, aerosol-generating articles in accordance with the present invention may advantageously be manufactured by assembling areduced number of components. This is because the wrapper combining the rod of aerosolgenerating substrate and the mouthpiece segment also forms the peripheral wall of the tubular segment defining the cavity, without the need for a separate hollow component to be provided in longitudinal arrangement with, and between, the rod of aerosol-generating substrate and the mouthpiece segment.

[0041] Furthermore, the inventors have observed that by adjusting one or more of select parameters of the wrapper - such as, for example, its thickness, basis weight and tensile strength - as will be described in detail below, it may be advantageously possible to control how rigidly the wrapper retains the components it circumscribes and, in particular, the longitudinally extending rod of aerosol-generating substrate. For example, in aerosol-generating articles according to the present invention, a wrapper having select values of one or more of thickness, basis weight and tensile strength may advantageously counter the tendency of the aerosol-generating substrate or the mouthpiece segment or both to swell due to their hygroscopic nature and water uptake, which may be undesired and can be somewhat unpredictable. Deviations from the nominal radial size of the rod of aerosol-generating substrate may thus desirably be contained.

[0042] This has benefits both during storage of the aerosol-generating articles as well as different stages during their manufacture. In fact, it is not uncommon for aerosol-generating articles to be produced according to a same article design at different manufacturing locations, wherein different combining equipment may be in use or wherein small specification oscillations occur. This degree of variability might leads to issues such as undesired gaps or steps appearing between components of an aerosol-generating article, which may become visible for the consumer. Issues are also possible when components are slightly longer than, or collectively at the upper end of, their allowable tolerance range, as this creates an excessive combined tolerance, leading to over-bunching and causing overhang at the ends, or kinking due to excess bending forces created due to the bunching.

[0043] In aerosol-generating articles according to the present invention, adjusting one or more of select parameters of the wrapper as will be described in detail below, makes it advantageously possible to counter and limit the appearance of similar gaps and steps, so that aerosol-generating articles can be consistently provided with an improved visual impact and generally closer to the intended article design.

[0044] As described briefly above, in aerosol-generating articles according to the present invention the wrapper circumscribes at least the rod of aerosol-generating substrate and the mouthpiece segment. In certain embodiments, the wrapper also circumscribes the upstream element.

[0045] This may advantageously further improve simplify the process in which the components mentioned so far are combined to form the aerosol-generating article. Additionally, such a wrapper extending substantially over the entire length of the aerosol-generating article andholding together all the components of the aerosol-generating article mentioned so far may beneficially improve the structural strength of the aerosol-generating article. Furthermore, considerations made above about the ability of the wrapper to counter the tendency of the rod of aerosol-generating substrate or of the mouthpiece segment to swell, for example in response to changes in the humidity level, are also applicable to the upstream element.

[0046] Preferably, in embodiments wherein the wrapper circumscribes the upstream element, both the upstream element and the wrapper extend all the way to an upstream end of the aerosolgenerating article. An aerosol-generating article including such a wrapper that extends substantially over the entire length of the aerosol-generating article may have a novel and distinguished visual impact on the consumer.

[0047] For example, in aerosol-generating articles according to the present invention the wrapper may have a thickness of at least 50 micrometres. Preferably, the wrapper has a thickness of at least 75 micrometres. More preferably, the wrapper has a thickness of at least 100 micrometres. Even more preferably, the wrapper has a thickness of at least 110 micrometres.

[0048] In aerosol-generating articles according to the present invention, the wrapper may, for example, have a thickness of up to 650 micrometres. Preferably, The wrapper has a thickness of less than or equal to 500 micrometres. More preferably, the wrapper has a thickness of less than or equal to 250 micrometres. Even more preferably, wrapper has a thickness of less than or equal to 150 micrometres.

[0049] In some examples, the wrapper may have a thickness from 50 micrometres to 650 micrometres, preferably from 75 micrometres to 650 micrometres, more preferably from 100 micrometres to 650 micrometres, even more preferably from 110 micrometres to 650 micrometres.

[0050] In other examples, the wrapper may have a thickness from 50 micrometres to 500 micrometres, preferably from 75 micrometres to 500 micrometres, more preferably from 100 micrometres to 500 micrometres, even more preferably from 110 micrometres to 500 micrometres.

[0051] In further examples, the wrapper may have a thickness from 50 micrometres to 250 micrometres, preferably from 75 micrometres to 250 micrometres, more preferably from 100 micrometres to 250 micrometres, even more preferably from 110 micrometres to 250 micrometres.

[0052] In yet other examples, the wrapper may have a thickness from 50 micrometres to 150 micrometres, preferably from 75 micrometres to 150 micrometres, more preferably from 100 micrometres to 150 micrometres, even more preferably from 110 micrometres to 150 micrometres.

[0053] For example, in aerosol-generating articles according to the present invention the wrapper may have a basis weight of at least 50 gsm. Preferably, the wrapper has a basis weight of atleast 60 gsm. More preferably, the wrapper has a basis weight of at least 70 gsm. Even more preferably, the wrapper has a basis weight of at least 75 gsm.

[0054] In aerosol-generating articles according to the present invention, the wrapper may, for example, have a basis weight of up to 140 gsm. Preferably, the wrapper has a basis weight of less than or equal to 130 gsm. More preferably, the wrapper has a basis weight of less than or equal to 120 gsm. Even more preferably, the wrapper has a basis weight of less than or equal to 110 gsm.

[0055] In some examples, the wrapper has a basis weight of from 50 gsm to 140 gsm, preferably from 50 gsm to 130 gsm, more preferably from 50 gsm to 120 gsm, even more preferably from 50 gsm to 110 gsm.

[0056] In other examples, the wrapper has a basis weight of from 60 gsm to 140 gsm, preferably from 60 gsm to 130 gsm, more preferably from 60 gsm to 120 gsm, even more preferably from 60 gsm to 110 gsm.

[0057] In further examples, the wrapper has a basis weight of from 70 gsm to 140 gsm, preferably from 70 gsm to 130 gsm, more preferably from 70 gsm to 120 gsm, even more preferably from 70 gsm to 110 gsm.

[0058] In yet further examples, the wrapper has a basis weight of from 75 gsm to 140 gsm, preferably from 75 gsm to 130 gsm, more preferably from 75 gsm to 120 gsm, even more preferably from 75 gsm to 110 gsm.

[0059] In aerosol-generating articles according to the present disclosure, the wrapper may for example have a tensile strength of at least 5 MPa. The tensile strength of a wrapper can be measured in accordance with ASTM D828 - 97 (Reapproved 2002) - Standard Test Method for Tensile properties of Paper and Paperboard Using Constant-Rate-of-Elongation Apparatus.

[0060] Preferably, the wrapper has a tensile strength of at least 10 MPa. More preferably, the wrapper has a tensile strength of at least 20 MPa. Even more preferably, the wrapper has a tensile strength of at least 30 MPa.

[0061] For example, in aerosol-generating articles according to the present invention the wrapper may have a tensile strength of up to 75 MPa. Preferably, the wrapper has a tensile strength of less than or equal to 70 MPa. More preferably, the wrapper has a tensile strength of less than or equal to 65 MPa. Even more preferably, the wrapper has a tensile strength of less than or equal to 60 MPa.

[0062] In some examples, the wrapper has a tensile strength of from 5 MPa to 75 MPa, preferably from 5 MPa to 70 MPa, more preferably from 5 MPa to 65 MPa, even more preferably from 5 MPa to 60 MPa.

[0063] In other examples, the wrapper has a tensile strength of from 10 MPa to 75 MPa, preferably from 10 MPa to 70 MPa, more preferably from 10 MPa to 65 MPa, even more preferably from 10 MPa to 60 MPa.In further examples, the wrapper has a tensile strength of from 20 MPa to 75 MPa, preferably from 20 MPa to 70 MPa, more preferably from 20 MPa to 65 MPa, even more preferably from 20 MPa to 60 MPa.

[0064] In yet other examples, the wrapper has a tensile strength of from 30 MPa to 75 MPa, preferably from 30 MPa to 70 MPa, more preferably from 30 MPa to 65 MPa, even more preferably from 30 MPa to 60 MPa.

[0065] As described briefly above, in an aerosol-generating article according to the present invention the wrapper forms a peripheral wall of a hollow tubular segment defining a cavity in longitudinal alignment with the rod and the mouthpiece segment. The cavity is arranged between the rod and the mouthpiece segment.

[0066] The cavity extends radially all the way to the wrapper. This means that an inner surface of the wrapper delimits the cavity in the radial direction and is immediately exposed to the aerosol flowing through the cavity.

[0067] The cavity extends longitudinally all the way to the mouthpiece segment. In certain preferred examples, the cavity extends from the rod of aerosol-generating substrate all the way to the mouthpiece segment. Even more precisely, the cavity extends from a downstream end of the rod of aerosol-generating substrate and an upstream end of the mouthpiece segment.

[0068] Thus, a length of the cavity substantially defines a distance between the rod of aerosolgenerating substrate and the mouthpiece segment measured longitudinally.

[0069] However, in other examples, the aerosol-generating article may further comprise an intermediate element in longitudinal arrangement with the rod and the mouthpiece segment, the intermediate element provided between the rod and the mouthpiece segment so that the cavity extends longitudinally all the way to a downstream end of the intermediate element. Advantageously, the provision of said intermediate element may further increase the structural strength and stability of the aerosol-generating article.

[0070] The intermediate element may comprise a plug of filtration material. In some examples, the intermediate element may comprise a hollow plug of filter material (for example, paper, cellulose acetate, etc.), an internal diameter of the hollow plug being smaller than a diameter of the cavity.

[0071] In aerosol-generating articles according to the present invention, a length of the cavity may for example be at least 5 millimetres. Preferably, a length of the cavity is at least 7 millimetres. More preferably, a length of the cavity is at least 10 millimetres. Even more preferably, a length of the cavity is at least 15 millimetres.

[0072] For example, a length of the cavity may less than 35 millimetres. Preferably, a length of the cavity is less than or equal to 30 millimetres. More preferably, a length of the cavity is less than or equal to 25 millimetres.In some examples, a length of the cavity is from 5 millimetres to 30 millimetres, preferably from 7 millimetres to 30 millimetres, more preferably from 10 millimetres to 30 millimetres, even more preferably from 15 millimetres to 30 millimetres.

[0073] In other examples, a length of the cavity is from 5 millimetres to 25 millimetres, preferably from 7 millimetres to 25 millimetres, more preferably from 10 millimetres to 25 millimetres, even more preferably from 15 millimetres to 25 millimetres.

[0074] In some preferred examples, a length of the cavity is from 20 millimetres to 35 millimetres or from 20 millimetres to 30 millimetres or from 20 millimetres to 25 millimetres. In some particularly preferred embodiments, a length of the cavity is from 20 millimetres to 22 millimetres.

[0075] Values of the length of the cavity falling within the ranges described above are beneficial in that the cavity is compatible with particularly satisfactory levels of aerosol nucleation and cooling of volatile species released upon heating the aerosol-generating substrate.

[0076] For example, a diameter of the cavity may be at least 6.5 millimetres. Preferably, a diameter of the cavity is at least 6.7 millimetres. More preferably, a diameter of the cavity is at least 6.8 millimetres.

[0077] A diameter of the cavity may for example be less than or equal to 7.5 millimetres. Preferably, a diameter of the cavity is less than or equal to 7.2 millimetres. More preferably, a diameter of the cavity is less than or equal to 7.1 millimetres.

[0078] In some examples, a diameter of the cavity is from 6.7 millimetres to 7.5 millimetres, preferably from 6.7 millimetres to 7.2 millimetres, more preferably from 6.7 millimetres to 7.1 millimetres. In other examples, a diameter of the cavity is from 6.7 millimetres to 7.5 millimetres, preferably from 6.5 millimetres to 7.2 millimetres, more preferably from 6.5 millimetres to 7.1 millimetres. In further examples, a diameter of the cavity is from 6.8 millimetres to 7.5 millimetres, preferably from 6.8 millimetres to 7.2 millimetres, more preferably from 6.8 millimetres to 7.1 millimetres.

[0079] In particularly preferred examples, a diameter of the cavity is from 6.85 millimetres to 6.95 millimetres.

[0080] A diameter of the cavity falls within the ranges described above is beneficial in that it is comparatively easy to wind or roll or wrap the wrapper so that it circumscribes the rod and the mouthpiece segment and forms the peripheral wall of the hollow tubular segment defining the cavity. By contrast, forming a cavity with a smaller diameter may become problematic, especially if using a thicker or less flexible wrapper.

[0081] At the same time, a diameter of the cavity falls within the ranges described above is beneficial in that it ensures that the hollow tubular segment defining the cavity, of which the wrapper forms the peripheral wall, has sufficient resistance to compressive loads applied both longitudinally and radially. In other words, values of the diameter of the cavity described above are associated with a satisfactory overall structural resistance of the aerosol-generating article.In preferred examples, a volume of the cavity is from 500 cubic millimetres to 1100 cubic millimetres, more preferably from 600 cubic millimetres to 1100 cubic millimetres, even more preferably from 700 cubic millimetres to 1100 cubic millimetres. For example, a volume of the cavity may be from 500 cubic millimetres to 1000 cubic millimetres or from 600 cubic millimetres to 1000 cubic millimetres or from 700 cubic millimetres to 1000 cubic millimetres or even from 500 cubic millimetres to 900 cubic millimetres or from 600 cubic millimetres to 900 cubic millimetres or from 700 cubic millimetres to 900 cubic millimetres.

[0082] In particularly preferred embodiments, a volume of the cavity is from 750 cubic millimetres to 850 cubic millimetres.

[0083] Values of the volume of the cavity falling within the ranges described above are beneficial in that the size of the cavity may favour nucleation and growth of aerosol particles so as to provide particularly satisfactory levels of aerosol delivery to the consumer.

[0084] An aerosol-generating article preferably further comprises a ventilation zone configured to enable air to flow into the cavity from an exterior of the aerosol-generating article.

[0085] In general, the term “ventilation zone” is used to denote one or more perforations establishing a fluid communication between the cavity and the exterior of the aerosol-generating article, so that when, during use, a consumer draws upon the mouthpiece segment, air is drawn from the exterior of the aerosol-generating article into the cavity through the one or more openings.

[0086] For example, the ventilation zone may comprise a row of ventilation perforations formed through a portion of the wrapper forming the peripheral wall of the hollow tubular segment and arranged circumferentially about a longitudinal axis of the aerosol-generating article. That is, the ventilation perforations are preferably formed through a portion of the wrapper comprised between the mouthpiece segment and the rod of aerosol-generating substrate.

[0087] A satisfactory cooling of the stream of aerosol generated upon heating the aerosolgenerating substrate and drawn through the cavity is achieved by providing a ventilation zone at a location comprised between the mouthpiece segment and the rod of aerosol-generating substrate. Without wishing to be bound by theory, it is understood that the temperature of the aerosol stream is rapidly lowered by the introduction of ventilation air as the aerosol travels towards the mouthpiece segment. Such a fast cooling of the aerosol stream has a favourable impact on the condensation and nucleation of aerosol particles, so much so that the enhanced nucleation may significantly counter the diluting effect caused by the introduction of ventilation air. Accordingly, delivery levels that are satisfactory for the consumer can be provided consistently.

[0088] A distance between the ventilation zone and an upstream end of the aerosol-generating article is for example less than or equal to 45 millimetres. Preferably, a distance between the ventilation zone and an upstream end of the aerosol-generating article is less than or equal to 40millimetres. More preferably, a distance between the ventilation zone and an upstream end of the aerosol-generating article is less than or equal to 35 millimetres. Even more preferably, a distance between the ventilation zone and an upstream end of the aerosol-generating article is less than or equal to 30 millimetres.

[0089] A distance between the ventilation zone and an upstream end of the aerosol-generating article is preferably at least 20 millimetres, more preferably at least 25 millimetres.

[0090] In some examples, a distance between the ventilation zone and an upstream end of the aerosol-generating article is from 20 millimetres to 45 millimetres, preferably from 20 millimetres to 40 millimetres, more preferably from 20 millimetres to 35 millimetres, even more preferably from 20 millimetres to 30 millimetres.

[0091] In other examples, a distance between the ventilation zone and an upstream end of the aerosol-generating article is from 25 millimetres to 45 millimetres, preferably from 25 millimetres to 40 millimetres, more preferably from 25 millimetres to 35 millimetres, even more preferably from 25 millimetres to 30 millimetres.

[0092] A distance between the ventilation zone and a downstream end of the aerosol-generating article is preferably less than or equal to 25 millimetres, more preferably less than or equal to 20 millimetres.

[0093] For example, a distance between the ventilation zone and a downstream end of the aerosol-generating article is at least 10 millimetres. Preferably, a distance between the ventilation zone and a downstream end of the aerosol-generating article is at least 12 millimetres. More preferably, a distance between the ventilation zone and a downstream end of the aerosolgenerating article is at least 14 millimetres. Even more preferably, a distance between the ventilation zone and a downstream end of the aerosol-generating article is at least 16 millimetres.

[0094] A distance between the ventilation zone and a downstream end of the aerosol-generating article is preferably less than or equal to 25 millimetres, more preferably less than or equal to 20 millimetres.

[0095] In certain examples, a distance between the ventilation zone and a downstream end of the aerosol-generating article is from 10 millimetres to 25 millimetres, preferably from 12 millimetres to 25 millimetres, more preferably from 14 millimetres to 25 millimetres, even more preferably from 16 millimetres to 25 millimetres.

[0096] In other examples, a distance between the ventilation zone and a downstream end of the aerosol-generating article is from 10 millimetres to 20 millimetres, preferably from 12 millimetres to 20 millimetres, more preferably from 14 millimetres to 20 millimetres, even more preferably from 16 millimetres to 20 millimetres.

[0097] In general, the inventors have found that selecting a location for the ventilation zone such that its distance from an upstream end of the aerosol-generating article, its distance from adownstream end of the aerosol-generating article, or both fall within the ranges described above is advantageous in that it is associated with desirable levels of nucleation of aerosol particles.

[0098] Without wishing to be bound by theory, it is hypothesised that, because the temperature of the aerosol stream is rapidly lowered by the introduction of ventilation air as the aerosol is travelling towards the mouth end of the aerosol-generating article, the ventilation air admitted into the aerosol stream at a location comparatively close to an upstream end of the hollow tubular segment (that is, comparatively close to the rod of aerosol-generating substrate), a dramatic cooling of the aerosol stream is achieved, which has a favourable impact on the condensation and nucleation of the aerosol particles. Accordingly, the overall proportion of the aerosol particulate phase to the aerosol gas phase may be enhanced.

[0099] At the same time, arranging the ventilation zone at a distance from the downstream end of the aerosol-generating article falling within the ranges described above, a cooling chamber is effectively provided immediately upstream of the mouthpiece, wherein nucleation and growth of aerosol particles are advantageously favoured. This has been found to at least partly counter the diluting effect of the ventilation air admitted into the hollow tubular segment, and so aerosol delivery levels that are satisfactory for the consumer may advantageously be provided.

[0100] In aerosol-generating articles according to the present invention, wherein the peripheral wall of the hollow tubular segment is formed by the wrapper circumscribing the rod of aerosolgenerating substrate and the mouthpiece, excessive condensation of aerosol upstream of the mouthpiece segment is undesirable, as a locally moistened wrapper might become structurally weaker. The inventors have found that arranging the ventilation zone at a distance from a downstream end of the aerosol-generating article falling within the ranges described above advantageously do not incur such undesirable levels of condensation and accumulated moisture, and so the structural integrity of the aerosol-generating article during use is desirably preserved.

[0101] The aerosol-generating substrate may be a solid aerosol-generating substrate.

[0102] In some embodiments, the aerosol-generating substrate comprises a plant material, such as tobacco plant material.

[0103] Particularly suitable types of materials for use in the aerosol-generating substrate are described below and include, for example, tobacco cut filler, homogenised tobacco material such as cast leaf, aerosol-generating films and gel compositions.

[0104] The aerosol-generating substrate preferably comprises an aerosol former. Suitable aerosol formers are for example: polyhydric alcohols such as, for example, triethylene glycol, 1 ,3-butanediol, propylene glycol and glycerine; esters of polyhydric alcohols such as, for example, glycerol mono-, di- or triacetate; aliphatic esters of mono-, di- or polycarboxylic acids such as, for example, dimethyl dodecanedioate and dimethyl tetradecanedioate; and combinations thereof.Preferably, the aerosol former comprises one or more of glycerine and propylene glycol. The aerosol former may consist of glycerine or propylene glycol or of a combination of glycerine and propylene glycol.

[0105] In certain embodiments, the aerosol-generating substrate preferably comprises at least 5 percent by weight of aerosol former on a dry weight basis of the aerosol-generating substrate, more preferably at least 10 percent by weight on a dry weight basis, more preferably at least 15 percent by weight on a dry weight basis. In such embodiments, the aerosol-generating substrate preferably comprises no more than 30 percent by weight of aerosol former on a dry weight basis of the aerosol-generating substrate, more preferably no more than 25 percent by weight on a dry weight basis, more preferably no more than 20 percent by weight on a dry weight basis. For example, the aerosol former content of the aerosol-generating substrate may be between 5 percent and 30 percent by weight, or between 10 percent and 25 percent by weight, or between about 15 percent and about 20 percent by weight, on a dry weight basis. In such embodiments, the aerosol former content is therefore relatively low.

[0106] In other embodiments, the aerosol-generating substrate preferably comprises at least 40 percent by weight of aerosol former on a dry weight basis of the aerosol-generating substrate, more preferably at least 45 percent by weight on a dry weight basis, more preferably at least 50 percent by weight on a dry weight basis. In such embodiments, the aerosol-generating substrate preferably comprises no more than 80 percent by weight of aerosol former on a dry weight basis of the aerosol-generating substrate, more preferably no more than 75 percent by weight on a dry weight basis, more preferably no more than 70 percent by weight on a dry weight basis. For example, the aerosol former content of the aerosol-generating substrate may be between 40 percent and 80 percent by weight, or between 45 percent and 75 percent by weight, or between about 50 percent and about 70 percent by weight, on a dry weight basis. In such embodiments, the aerosol former content is therefore relatively high.

[0107] In some preferred embodiments, the aerosol-generating substrate comprises tobacco material. For example, the aerosol-generating substrate may comprise shredded tobacco material. For example, the shredded tobacco material may be in the form of cut filler, as described in more detail below. Alternatively, the shredded tobacco material may be in the form of a shredded sheet of homogenised tobacco material. Suitable homogenised tobacco materials for use in the present invention are described below.

[0108] Within the context of the present specification, the term “cut filler” is used to describe to a blend of shredded plant material, such as tobacco plant material, including, in particular, one or more of leaf lamina, processed stems and ribs, homogenised plant material.

[0109] The cut filler suitable to be used with the present invention generally may resemble cut filler used for conventional smoking articles. The cut width of the cut filler preferably may bebetween 0.3 millimetres and 2.0 millimetres, or between 0.5 millimetres and 1.2 millimetres, or between 0.6 millimetres and 0.9 millimetres.

[0110] Preferably, the strands have a length of between about 10 millimetres and about 40 millimetres before the strands are collated to form the rod of aerosol-generating substrate.

[0111] Preferably, the cut filler is soaked with the aerosol former. Soaking the cut filler can be done by spraying or by other suitable application methods. Preferably, the aerosol former in the cut filler comprises one or more of glycerol and propylene glycol. The aerosol former may consist of glycerol or propylene glycol or of a combination of glycerol and propylene glycol.

[0112] In other preferred embodiments, the aerosol-generating substrate comprises homogenised plant material, preferably a homogenised tobacco material.

[0113] As used herein, the term “homogenised plant material” encompasses any plant material formed by the agglomeration of particles of plant material. The plant material may a non-tobacco plant material and may comprise particles of one or more of: tea, coffee, star anise, lavender, clove, peppermint, chamomile, rosemary, eucalyptus, ginger, dill seed, thyme, oregano and cumin. With reference to a non-tobacco plant, the term plant material may refer to one or more of the plant leaf (lamina, stems, stalk), flowers, seeds, and so forth.

[0114] The plant material may be a tobacco plant material. For example, sheets or webs of homogenised tobacco material for the aerosol-generating substrates of the present invention may be formed by agglomerating particles of tobacco material obtained by pulverising, grinding or comminuting plant material and optionally one or more of tobacco leaf lamina and tobacco leaf stems. The homogenised plant material may be produced by casting, extrusion, paper making processes or other any other suitable processes known in the art.

[0115] The homogenised plant material can be provided in any suitable form.

[0116] In some embodiments, the homogenised plant material may be in the form of one or more sheets. As used herein with reference to the invention, the term “sheet” describes a laminar element having a width and length substantially greater than the thickness thereof.

[0117] The homogenised plant material may be in the form of a plurality of pellets or granules. The homogenised plant material may be in the form of a plurality of strands, strips or shreds. As used herein, the term “strand” describes an elongate element of material having a length that is substantially greater than the width and thickness thereof. The strands may be arranged substantially randomly within the rod of aerosol-generating article. As an alternative, the strands may be arranged substantially parallel to each other and to a longitudinal axis of the rod of aerosol-generating substrate.

[0118] The aerosol former content of the homogenised tobacco material is preferably within the ranges defined above for aerosol-generating substrate having a relatively low aerosol former content.In other preferred embodiments, the aerosol-generating substrate is in the form of an aerosol-generating film comprising a cellulosic based film-forming agent, nicotine and the aerosol former. The aerosol-generating film may further comprise a cellulose based strengthening agent. The aerosol-generating film may further comprise water, preferably 30 percent by weight of less of water.

[0119] As used herein, the term “film” is used to describe a solid laminar element having a thickness that is less than the width or length thereof. The film may be self-supporting.

[0120] In the context of the present invention the term “cellulose based film-forming agent” is used to describe a cellulosic polymer capable, by itself or in the presence of an auxiliary thickening agent, of forming a continuous film. Preferably, the cellulose based film-forming agent is selected from the group consisting of hydroxypropyl methylcellulose (HPMC), methylcellulose (MC), ethyl cellulose (EC), hydroxyethyl methyl cellulose (HEMC), hydroxyethyl cellulose (HEC), hydroxypropyl cellulose (HPC), and combinations thereof. In particularly preferred embodiments, the cellulose based film-forming agent is HPMC.

[0121] The aerosol former content of the aerosol-generating film is within the ranges defined above for aerosol-generating substrates having a relatively high aerosol former content.

[0122] Suitable aerosol-generating films for use as the aerosol-generating substrate of aerosolgenerating articles according to the invention are described in WO-A-2020 / 207733 and WO-A-2022 / 074157.

[0123] Preferably, the aerosol-generating film comprises between 0.5 percent and 10 percent by weight of nicotine, or between 1 percent and 8 percent by weight of nicotine, or between 2 percent and 6 percent by weight of nicotine, on a dry weight basis.

[0124] The aerosol-generating film may be a substantially tobacco-free aerosol-generating film. In alternative embodiments of the invention, the aerosol-generating substrate may comprise a gel composition that includes nicotine, at least one gelling agent and the aerosol former. The gel composition is preferably substantially tobacco free.

[0125] The preferred weight ranges for nicotine in the gel composition are the same as those defined above in relation to aerosol-generating films.

[0126] Suitable gel compositions for use as the aerosol-generating substrate of aerosolgenerating articles according to the invention are described in WO-A-2021 / 170642.

[0127] The gel composition preferably comprises at least 50 percent by weight of aerosol former, more preferably at least 60 percent by weight, more preferably at least 70 percent by weight of aerosol former, on a dry weight basis. The gel composition may comprise up to 80 percent by weight of aerosol former. The aerosol former in the gel composition is preferably glycerol.

[0128] A length of the rod of aerosol-generating substrate may be at leasts millimetres or at least 5 millimetres or at least 7 millimetres.The length of the rod of aerosol-generating substrate may be less than or equal to 25 millimetres or less than or equal to 20 millimetres or less than or equal to 15 millimetres.

[0129] In some examples, the length of the rod of aerosol-generating substrate may be from 3 millimetres to 25 millimetres, preferably from 5 millimetres to 25 millimetres, more preferably from 7 millimetres to 25 millimetres.

[0130] In other examples, the length of the rod of aerosol-generating substrate may be from 3 millimetres to 20 millimetres, preferably from 5 millimetres to 20 millimetres, more preferably from 7 millimetres to 20 millimetres.

[0131] In further examples, the length of the rod of aerosol-generating substrate may be from 3 millimetres to 15 millimetres, preferably from 5 millimetres to 15 millimetres, more preferably from 7 millimetres to 15 millimetres.

[0132] In some particularly preferred examples, the length of the rod of aerosol-generating substrate is from 8 millimetres to 14 millimetres.

[0133] A diameter of the rod of aerosol-generating substrate may be at least 5 millimetres or at least 6 millimetres or at least 6.5 millimetres. Preferably, a diameter of the rod of aerosolgenerating substrate is at least 6.7 millimetres, more preferably at least 6.8 millimetres.

[0134] The diameter of the rod of aerosol-generating substrate may be less than or equal to 9 millimetres or less than or equal to 8 millimetres or less than or equal to 7.5 millimetres. Preferably, a diameter of the rod of aerosol-generating substrate is less than or equal to 7.2 millimetres, more preferably less than or equal to 7.1 millimetres.

[0135] In some examples, the diameter of the rod of aerosol-generating substrate may be from 5 millimetres to 9 millimetres, preferably from 6 millimetres to 9 millimetres, more preferably from 6.5 millimetres to 9 millimetres. In preferred examples, the diameter of the rod of aerosolgenerating substrate is from 6.7 millimetres to 9 millimetres, more preferably from 6.8 millimetres to 9 millimetres.

[0136] In other examples, the diameter of the rod of aerosol-generating substrate may be from 5 millimetres to 8 millimetres, preferably from 6 millimetres to 8 millimetres, more preferably from 6.5 millimetres to 8 millimetres. In preferred examples, the diameter of the rod of aerosolgenerating substrate is from 6.7 millimetres to 8 millimetres, more preferably from 6.8 millimetres to 8 millimetres.

[0137] In further examples, the diameter of the rod of aerosol-generating substrate may be from 5 millimetres to 7.5 millimetres, preferably from 6 millimetres to 7.5 millimetres, more preferably from 6.5 millimetres to 7.5 millimetres. In preferred examples, the diameter of the rod of aerosolgenerating substrate is from 6.7 millimetres to 7.5 millimetres, more preferably from 6.8 millimetres to 7.5 millimetres.

[0138] In yet further examples, the diameter of the rod of aerosol-generating substrate may be from 5 millimetres to 7.2 millimetres, preferably from 6 millimetres to 7.2 millimetres, morepreferably from 6.5 millimetres to 7.2 millimetres. In preferred examples, the diameter of the rod of aerosol-generating substrate is from 6.7 millimetres to 7.2 millimetres, more preferably from 6.8 millimetres to 7.2 millimetres.

[0139] In another set of examples, the diameter of the rod of aerosol-generating substrate may be from 5 millimetres to 7.1 millimetres, preferably from 6 millimetres to 7.1 millimetres, more preferably from 6.5 millimetres to 7.1 millimetres. In preferred examples, the diameter of the rod of aerosol-generating substrate is from 6.7 millimetres to 7.1 millimetres, more preferably from 6.8 millimetres to 7.1 millimetres.

[0140] In some particularly preferred examples, the diameter of the rod of aerosol-generating substrate is from 6.85 millimetres to 6.95 millimetres.

[0141] In certain examples, an aerosol-generating article in accordance with the present invention may further comprise one or more susceptor elements within the rod of aerosolgenerating substrate. As used herein with reference to the present invention, the term “susceptor element” refers to a material that can convert electromagnetic energy into heat.

[0142] For example, the aerosol-generating article may comprise one or more elongate susceptor elements arranged within the rod of aerosol-generating substrate. In certain embodiments, the one or more elongate susceptor elements may be arranged substantially longitudinally within the rod of aerosol-generating substrate and in thermal contact with the aerosol-generating substrate.

[0143] Suitable susceptor elements for use in the aerosol-generating substrate of aerosolgenerating articles according to the present invention are described in WO-A-2021 / 170673.

[0144] In aerosol-generating articles according to the present invention, a ratio between a thickness of the wrapper and a diameter of the rod may, for example, be at least 0.012. Preferably, a ratio between a thickness of the wrapper and a diameter of the rod is at least 0.014. More preferably, a ratio between a thickness of the wrapper and a diameter of the rod is at least 0.016. Even more preferably, a ratio between a thickness of the wrapper and a diameter of the rod is at least 0.018.

[0145] For example, in aerosol-generating articles according to the present invention a ratio between a thickness of the wrapper and a diameter of the rod may be up to 0.17. Preferably, a ratio between a thickness of the wrapper and a diameter of the rod is less than or equal to 0.167. More preferably, a ratio between a thickness of the wrapper and a diameter of the rod is less than or equal to 0.15. Even more preferably, a ratio between a thickness of the wrapper and a diameter of the rod is less than or equal to 0.1. In particularly preferred embodiments, a ratio between a thickness of the wrapper and a diameter of the rod is less than or equal to 0.05.

[0146] In some examples, a ratio between a thickness of the wrapper and a diameter of the rod is from 0.012 to 0.17, preferably from 0.014 to 0.17, more preferably from 0.016 to 0.17, even more preferably from 0.018 to 0.17.In other examples, a ratio between a thickness of the wrapper and a diameter of the rod is from 0.012 to 0.167, preferably from 0.014 to 0.167, more preferably from 0.016 to 0.167, even more preferably from 0.018 to 0.167.

[0147] In further examples, a ratio between a thickness of the wrapper and a diameter of the rod is from 0.012 to 0.15, preferably from 0.014 to 0.15, more preferably from 0.016 to 0.15, even more preferably from 0.018 to 0.15.

[0148] In yet further examples, a ratio between a thickness of the wrapper and a diameter of the rod is from 0.012 to 0.1, preferably from 0.014 to 0.1, more preferably from 0.016 to 0.1, even more preferably from 0.018 to 0.1.

[0149] In another set of examples, a ratio between a thickness of the wrapper and a diameter of the rod is from 0.012 to 0.05, preferably from 0.014 to 0.05, more preferably from 0.016 to 0.05, even more preferably from 0.018 to 0.05.

[0150] As described briefly above, an aerosol-generating article in accordance with the present disclosure comprises a mouthpiece segment at the downstream end or mouth end or proximal end of the aerosol-generating article.

[0151] The mouthpiece segment may comprise a single plug element comprising filtration material. As an alternative, the mouthpiece segment may comprise two or more components, such as for example a plug element comprising filtration material paired with a hollow tubular element arranged downstream of the plug element and defining a recess at a mouth end of the aerosol-generating article.

[0152] The mouthpiece segment may have a low particulate phase filtration efficiency or even substantially no particulate phase filtration efficiency. Whilst capable of preventing substrate material from the aerosol-generating element potentially reaching the mouth of the consumer during use, a mouthpiece segment having low particulate phase filtration efficiency has a reduced impact on delivery of aerosol species to the consumer. This is especially advantageous in an aerosol-generating article wherein the aerosol-generating substrate is heated as opposed to being combusted.

[0153] Where the mouthpiece segment comprises plug element comprising filtration material, the mouthpiece segment may further comprise an individual plug wrap circumscribing the plug element. Thus, in the aerosol-generating article, the wrapper circumscribes the individual plug wrap and the underlying plug element.

[0154] The mouthpiece segment is preferably unventilated such that air from the exterior of the aerosol-generating article does not enter the aerosol-generating article along the mouthpiece segment.

[0155] A length of the mouthpiece segment may be at least 3 millimetres or at least 5 millimetres or at least 6 millimetres.The length of the mouthpiece segment may be less than or equal to 15 millimetres or less than or equal to 12 millimetres or less than or equal to 10 millimetres.

[0156] In some examples, the length of the mouthpiece segment may be from 3 millimetres to 15 millimetres, preferably from 5 millimetres to 15 millimetres, more preferably from 6 millimetres to 15 millimetres.

[0157] In other examples, the length of the mouthpiece segment may be from 3 millimetres to 12 millimetres, preferably from 5 millimetres to 12 millimetres, more preferably from 6 millimetres to 12 millimetres.

[0158] In further examples, the length of the mouthpiece segment may be from 3 millimetres to 10 millimetres, preferably from 5 millimetres to 10 millimetres, more preferably from 6 millimetres to 10 millimetres.

[0159] In some particularly preferred examples, the length of the mouthpiece segment is from 6.5 millimetres to 7.5 millimetres.

[0160] The length of the mouthpiece segment may, for example, be selected based on a desired total length of the aerosol-generating article.

[0161] A diameter of the mouthpiece segment may be at least 5 millimetres or at least 6 millimetres or at least 6.5 millimetres.

[0162] The diameter of the mouthpiece segment may be less than or equal to 9 millimetres or less than or equal to 8 millimetres or less than or equal to 7.5 millimetres.

[0163] In some examples, the diameter of the mouthpiece segment may be from 5 millimetres to 9 millimetres, preferably from 6 millimetres to 9 millimetres, more preferably from 6.5 millimetres to 9 millimetres.

[0164] In other examples, the diameter of the mouthpiece segment may be from 5 millimetres to 8 millimetres, preferably from 6 millimetres to 8 millimetres, more preferably from 6.5 millimetres to 8 millimetres.

[0165] In further examples, the diameter of the mouthpiece segment may be from 5 millimetres to 7.5 millimetres, preferably from 6 millimetres to 7.5 millimetres, more preferably from 6.5 millimetres to 7.5 millimetres.

[0166] In some particularly preferred examples, the diameter of the mouthpiece segment is from 7.1 millimetres to 7.3 millimetres.

[0167] In aerosol-generating articles according to the present invention, a ratio between a thickness of the wrapper and a diameter of the mouthpiece segment may, for example, be at least 0.012. Preferably, a ratio between a thickness of the wrapper and a diameter of the mouthpiece segment is at least 0.014. More preferably, a ratio between a thickness of the wrapper and a diameter of the mouthpiece segment is at least 0.016. Even more preferably, a ratio between a thickness of the wrapper and a diameter of the mouthpiece segment is at least 0.018.For example, in aerosol-generating articles according to the present invention a ratio between a thickness of the wrapper and a diameter of the mouthpiece segment may be up to 0.17. Preferably, a ratio between a thickness of the wrapper and a diameter of the mouthpiece segment is less than or equal to 0.167. More preferably, a ratio between a thickness of the wrapper and a diameter of the mouthpiece segment is less than or equal to 0.15. Even more preferably, a ratio between a thickness of the wrapper and a diameter of the mouthpiece segment is less than or equal to 0.1. In particularly preferred embodiments, a ratio between a thickness of the wrapper and a diameter of the mouthpiece segment is less than or equal to 0.05.

[0168] In some examples, a ratio between a thickness of the wrapper and a diameter of the mouthpiece segment is from 0.012 to 0.17, preferably from 0.014 to 0.17, more preferably from 0.016 to 0.17, even more preferably from 0.018 to 0.17.

[0169] In other examples, a ratio between a thickness of the wrapper and a diameter of the mouthpiece segment is from 0.012 to 0.167, preferably from 0.014 to 0.167, more preferably from 0.016 to 0.167, even more preferably from 0.018 to 0.167.

[0170] In further examples, a ratio between a thickness of the wrapper and a diameter of the mouthpiece segment is from 0.012 to 0.15, preferably from 0.014 to 0.15, more preferably from 0.016 to 0.15, even more preferably from 0.018 to 0.15.

[0171] In yet further examples, a ratio between a thickness of the wrapper and a diameter of the mouthpiece segment is from 0.012 to 0.1, preferably from 0.014 to 0.1, more preferably from 0.016 to 0.1, even more preferably from 0.018 to 0.1.

[0172] In another set of examples, a ratio between a thickness of the wrapper and a diameter of the mouthpiece segment is from 0.012 to 0.05, preferably from 0.014 to 0.05, more preferably from 0.016 to 0.05, even more preferably from 0.018 to 0.05.

[0173] As described briefly above, an aerosol-generating article according to the present invention comprises an upstream element provided upstream of the rod, in longitudinal alignment with the rod and abutting an upstream end of the rod.

[0174] The upstream element provides a degree of protection to the aerosol-generating substrate during storage, as it covers at least to some extent the upstream end of the rod of aerosolgenerating substrate, which may otherwise be exposed. For aerosol-generating articles that are intended to be inserted into a heating cavity in an aerosol-generating device during use, such that the aerosol-generating substrate can be heated, the upstream element may advantageously facilitate the insertion of the upstream end of the article into the heating cavity and maintain the aerosol-generating substrate at a predetermined location within the heating cavity.

[0175] Where the aerosol-generating substrate comprises shredded tobacco, such as tobacco cut filler, the upstream element may additionally help to prevent the loss of loose particles of tobacco from the distal end of the article.An upstream element may be made of any material suitable for use in an aerosolgenerating article. The upstream element may, for example, be made of the same material used for the mouthpiece segment, the geometry and function of which have been described above. Suitable materials for forming the upstream element include common filter materials, such as for example paper, cardboard and cellulose acetate, as well as ceramic and polymeric materials, zeolites, etc. In some embodiments, the upstream element may comprise a further source of aerosol or a flavourant, for example provided in a frangible capsule.

[0176] In certain embodiments, the upstream element comprises a plug element comprising a filtration material. For example, the upstream element may comprise a plug element be formed of the same filtration material as the mouthpiece segment described above.

[0177] Where the upstream element comprises a plug element comprising filtration material, the upstream element may further comprise an individual plug wrap circumscribing the plug element. Thus, in certain embodiments of the aerosol-generating article wherein the wrapper circumscribes the upstream element, the wrapper circumscribes the individual plug wrap and the underlying plug element.

[0178] A length of the upstream element may be at least 2 millimetres or at least 3 millimetres or at least 4 millimetres.

[0179] The length of the upstream element may be less than or equal to 12 millimetres or less than or equal to 10 millimetres or less than or equal to 8 millimetres.

[0180] In some examples, the length of the upstream element may be from 2 millimetres to 12 millimetres, preferably from 3 millimetres to 12 millimetres, more preferably from 4 millimetres to 12 millimetres.

[0181] In other examples, the length of the upstream element may be from 2 millimetres to 10 millimetres, preferably from 3 millimetres to 10 millimetres, more preferably from 4 millimetres to 10 millimetres.

[0182] In further examples, the length of the upstream element may be from 2 millimetres to 8 millimetres, preferably from 3 millimetres to 8 millimetres, more preferably from 4 millimetres to 8 millimetres.

[0183] In yet further examples, the length of the upstream element is from 5 millimetres to 12 millimetres or from 5 millimetres to 10 millimetres or from 5 millimetres to 8 millimetres. In some particularly preferred examples, the length of the upstream element is from 5 millimetres to 6 millimetres.

[0184] The length of the upstream element may, for example, be selected based on a desired total length of the aerosol-generating article.

[0185] A diameter of the upstream element may be at least 5 millimetres or at least 6 millimetres or at least 6.5 millimetres.The diameter of the upstream element may be less than or equal to 9 millimetres or less than or equal to 8 millimetres or less than or equal to 7.5 millimetres.

[0186] In some examples, the diameter of the upstream element may be from 5 millimetres to 9 millimetres, preferably from 6 millimetres to 9 millimetres, more preferably from 6.5 millimetres to 9 millimetres.

[0187] In other examples, the diameter of the upstream element may be from 5 millimetres to 8 millimetres, preferably from 6 millimetres to 8 millimetres, more preferably from 6.5 millimetres to 8 millimetres.

[0188] In further examples, the diameter of the upstream element may be from 5 millimetres to 7.5 millimetres, preferably from 6 millimetres to 7.5 millimetres, more preferably from 6.5 millimetres to 7.5 millimetres.

[0189] In some particularly preferred examples, the diameter of the upstream element is from 6.7 millimetres to 7.2 millimetres or from 6.7 millimetres to 7.1 millimetres or from 6.7 millimetres to 7.05 millimetres. In other particularly preferred examples, the diameter of the upstream element is from 6.8 millimetres to 7.2 millimetres or from 6.8 millimetres to 7.1 millimetres or from 6.8 millimetres to 7.05 millimetres. In further particularly preferred examples, the diameter of the upstream element is from 6.9 millimetres to 7.2 millimetres or from 6.9 millimetres to 7.1 millimetres or from 6.9 millimetres to 7.05 millimetres. In yet further particularly preferred examples, the diameter of the upstream element is from 6.95 millimetres to 7.2 millimetres or from 6.95 millimetres to 7.1 millimetres or from 6.95 millimetres to 7.05 millimetres.

[0190] An aerosol-generating article according to the present invention may further comprise a band of tipping paper circumscribing the wrapper. A length of the band of tipping paper is less than a length of the wrapper, and the band of tipping paper may be applied so that it extends from a mouth end of the aerosol-generating article to an intermediate location between the mouth end and the distal end of the aerosol-generating article. As such, the band of tipping paper extends over the entire length of the mouthpiece segment and over at least part of the length of the hollow tubular segment.

[0191] For example, a length of the tipping paper may be such that the band of tipping paper circumscribes the mouthpiece segment entirely and at least 25 percent of the hollow tubular segment. Preferably, a length of the tipping paper is such that the band of tipping paper circumscribes the mouthpiece segment entirely and at least 50 percent of the hollow tubular segment. More preferably, a length of the tipping paper is such that the band of tipping paper circumscribes the mouthpiece segment entirely and at least 75 percent of the hollow tubular segment. In some preferred examples, a length of the tipping paper is such that the band of tipping paper circumscribes the mouthpiece segment entirely and at least 85 percent of the hollow tubular segment or at least 90 percent of the hollow tubular segment.Adjusting the length of the tipping paper so that it circumscribes the mouthpiece segment and a certain portion of the hollow tubular segment as described above may impart the aerosolgenerating article a novel visual impact, which may be customised. At the same time, selecting such suitable values for the length of the tipping paper may improve the structural strength of the aerosol-generating article, particularly at locations downstream of the ventilation zone.

[0192] For example, a length of the band of tipping paper may be at least 7 millimetres or at least 10 millimetres or at least 15 millimetres. A length of the band of tipping paper may be less than or equal to 35 millimetres or less than or equal to 30 millimetres or less than or equal to 25 millimetres. In particularly preferred embodiments, a length of the tipping paper is from 19 millimetres to 21 millimetres.

[0193] Where a band of tipping paper is present and extends over the location of the ventilation zone, the perforations of the ventilation zone are formed not only through the wrapper but also through the overlying band of tipping paper.

[0194] A thickness of the band of tipping paper may be from 0.02 millimetres to 0.04 millimetres. In certain examples, an aerosol-generating article according to the present invention may further comprise indicia applied on a region of an outer surface of the wrapper, the region extending longitudinally from a downstream end of the article to a location along the cavity.

[0195] An overall length of an aerosol-generating article in accordance with the invention is for example be at least 30 millimetres, preferably at least 35 millimetres, more preferably at least 40 millimetres. For example, an overall length of an aerosol-generating article in accordance with the invention may be less than or equal to 100 millimetres, preferably less than or equal to 80 millimetres, more preferably less than 60 millimetres, even more preferably less than 50 millimetres.

[0196] In some examples, an overall length of the aerosol-generating article is from 30 millimetres to 100 millimetres, preferably from 35 millimetres to 100 millimetres, more preferably from 40 millimetres to 100 millimetres. In other examples, an overall length of the aerosol-generating article is from 30 millimetres to 80 millimetres, preferably from 35 millimetres to 80 millimetres, more preferably from 40 millimetres to 80 millimetres. In further examples, an overall length of the aerosol-generating article is from 30 millimetres to 60 millimetres, preferably from 35 millimetres to 60 millimetres, more preferably from 40 millimetres to 60 millimetres. In yet further examples, an overall length of the aerosol-generating article is from 30 millimetres to 50 millimetres, preferably from 35 millimetres to 50 millimetres, more preferably from 40 millimetres to 50 millimetres. In particularly preferred examples, an overall length of the aerosol-generating article is from 42 millimetres to 48 millimetres.

[0197] In addition, or as an alternative, an overall length of the aerosol-generating article in accordance with the invention is preferably less than about 70 millimetres, more preferably less than 60 millimetres, even more preferably less than 50 millimetres. In preferred embodiments,an overall length of the aerosol-generating article is from about 40 millimetres to about 70 millimetres. In an exemplary embodiment, an overall length of the aerosol-generating article is about 45 millimetres.

[0198] The aerosol-generating articles disclosed herein may be paired with a suitable aerosolgenerating device to provide an aerosol-generating system.

[0199] As described briefly above, an aerosol-generating system for producing an inhalable aerosol may comprise an aerosol-generating article in line with the foregoing description and an aerosol-generating device comprising a heating arrangement configured to heat at least a portion of the aerosol-generating substrate to generate an aerosol.

[0200] For example, the aerosol-generating device may comprise a heating chamber adapted to at least partly receive the aerosol-generating article to supply heat to the aerosol-generating element. The aerosol-generating device may for example comprise one or more heating element configured to be positioned externally of the aerosol-generating article when the aerosolgenerating article is received within the heating chamber.

[0201] Aerosol-generating articles in accordance with the foregoing description may advantageously be manufactured by making only small adjustments to existing processes and equipment.

[0202] A suitable manufacturing method may comprise a first step of providing a plurality of rods of aerosol-generating substrate comprising an aerosol former, a plurality of first plugs of filter material, and a plurality of second plugs of filter material.

[0203] The method may further comprise a second step of arranging the rods of aerosolgenerating substrate, the first plugs of filter material and the second plugs of filter material to form a plurality of arrays on respective strips of wrapper material. In each array a first plug of filter material is provided between a pair of rods of aerosol-generating substrate, and a gap having a predetermined length is provided between the first plug of filter material and each rod of aerosolgenerating substrate. Further, in each array the first plug of filter material and the pair of rods of aerosol-generating substrate are provided between a pair of second plugs of filter material. Each second plug of filter material is adjacent to a respective rod of aerosol-generating substrate.

[0204] Thus, each array comprises, in sequential order: a second plug of filter material, a rod of aerosol-generating substrate, a gap, a first plug of filter material, a gap, a rod of aerosolgenerating material, and a second plug of filter material.

[0205] The method may further comprise a third step of wrapping each array with the strip of wrapper material to form a wrapped array, wherein the first plug of filter material, the pair of rods of aerosol-generating substrate and the pair of second plugs of filter material are permanently secured to the strip of wrapper material. To this purpose, a layer of adhesive may be applied on each strip of wrapper material prior to carrying out the second step.The method may further comprise a fourth step of cutting each wrapped array at an intermediate position along each first plug of filter material to provide multiple wrapped assemblies, wherein each wrapped assembly comprises a second plug of filter material a rod of aerosol-generating material, and a mouthpiece segment, a gap having the predetermined length being provided between the mouthpiece segment and the rod of aerosol-generating substrate. In each wrapped assembly, the strip of wrapper material forms a peripheral wall of a hollow tubular segment defining a cavity in longitudinal alignment with, and arranged between, the rod of aerosol-generating substrate and the mouthpiece segment. In more detail, the cavity extends longitudinally between the rod of aerosol-generating substrate and the mouthpiece segment and radially all the way to the peripheral wall.

[0206] Each wrapped assembly is in fact an aerosol-generating article according to foregoing disclosure.

[0207] Preferably, the method may comprise a further step of applying a band of tipping paper around each wrapper assembly, wherein the band of tipping paper circumscribes the mouthpiece segment and at least a portion of the hollow tubular segment. Additionally, or as an alternative, the method may comprise a further step of applying indicia on an outer surface of each wrapped assembly, preferably at a location along the mouthpiece segment, the hollow tubular segment or both.

[0208] In some examples, the method may comprise an additional step of optically monitoring each array prior to carrying out the third step described above. Optically monitoring each array may comprise one or more of the following: checking that the rods of aerosol-generating substrate, the first plugs of filter material and the second plugs of filter material are arranged in the intended sequential order; checking that each gap provided between the first plug of filter material and each rod of aerosol-generating substrate has the intended length; checking that each second plug of filter material is adjacent to the respective rod of aerosol-generating substrate; checking that none of the rods of aerosol-generating substrate, the first plugs of filter material and the second plugs of filter material are twisted.

[0209] The invention is defined in the claims. However, 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.

[0210] Example EX1: An aerosol-generating article for producing an inhalable aerosol upon heating, the aerosol-generating article comprising: a rod of aerosol-generating substrate comprising an aerosol former; an upstream element provided upstream of the rod, in longitudinal alignment with the rod and abutting an upstream end of the rod; a mouthpiece segment arranged downstream of the rod and in longitudinal alignment with the rod; a wrapper circumscribing the rod and the mouthpiece segment, the wrapper forming a peripheral wall of a hollow tubularsegment defining a cavity in longitudinal alignment with the rod and the mouthpiece segment, the cavity arranged between the rod and the mouthpiece segment; wherein the cavity extends longitudinally all the way to the mouthpiece segment and radially all the way to the wrapper.

[0211] Example EX 2: An aerosol-generating article according to example EX1, wherein the wrapper further circumscribes the upstream element and wherein the upstream element and the wrapper extend all the way to an upstream end of the aerosol-generating article.

[0212] Example EX3: An aerosol-generating article according to example EX1 or example EX2, wherein the wrapper has a thickness of at least 100 micrometres.

[0213] Example EX4: An aerosol-generating article according to any one of examples EX1 to EX3, wherein the wrapper has a thickness of less than or equal to 500 micrometres.

[0214] Example EX5: An aerosol-generating article according to any one of examples EXs 1 to 3, wherein the wrapper has a thickness of less than or equal to 250 micrometres.

[0215] Example EX6: An aerosol-generating article according to any one of examples EX1 to EX3, wherein the wrapper has a thickness of less than or equal to 150 micrometres.

[0216] Example EX7: An aerosol-generating article according to any one of examples EX1 to EX6, wherein a the wrapper has a basis weight of at least 70 gsm.

[0217] Example EX8: An aerosol-generating article according to any one of examples EX1 to EX6, wherein a the wrapper has a basis weight of at least 75 gsm.

[0218] Example EX9: An aerosol-generating article according to any one of examples EX1 to EX8, wherein a the wrapper has a basis weight of less than or equal to 130 gsm.

[0219] Example EX10: An aerosol-generating article according to any one of examples EX1 to EX8, wherein a the wrapper has a basis weight of less than or equal to 120 gsm.

[0220] Example EX11: An aerosol-generating article according to any one of examples EX1 to EX8, wherein a the wrapper has a basis weight of less than or equal to 110 gsm.

[0221] Example EX12: An aerosol-generating article according to any one of examples EX1 to EX11, wherein the wrapper has a tensile strength of at least 10 MPa.

[0222] Example EX13: An aerosol-generating article according to any one of examples EX1 to EX11 , wherein the wrapper has a tensile strength of at least 20 MPa.

[0223] Example EX14: An aerosol-generating article according to any one of examples EX1 to EX11, wherein the wrapper has a tensile strength of at least 30 MPa.

[0224] Example EX15: An aerosol-generating article according to any one of examples EX1 to EX14, wherein the wrapper has a tensile strength of less than or equal to 50 MPa.

[0225] Example EX16: An aerosol-generating article according to any one of examples EX1 to EX15 further comprising a ventilation zone to enable air to flow into the cavity from an exterior of the aerosol-generating article.Example EX17: An aerosol-generating article according to example EX16, wherein the ventilation zone comprises a row of ventilation perforations formed through the wrapper and arranged circumferentially about a longitudinal axis of the aerosol-generating article.

[0226] Example EX18: An aerosol-generating article according to example EX16 or EX17, wherein a distance between the ventilation zone and an upstream end of the aerosol-generating article is less than or equal to 45 millimetres.

[0227] Example EX19: An aerosol-generating article according to example EX16 or EX17, wherein a distance between the ventilation zone and an upstream end of the aerosol-generating article is less than or equal to 40 millimetres.

[0228] Example EX20: An aerosol-generating article according to example EX16 or EX17, wherein a distance between the ventilation zone and an upstream end of the aerosol-generating article is less than or equal to 35 millimetres.

[0229] Example EX21: An aerosol-generating article according to example EX16 or EX17, wherein a distance between the ventilation zone and an upstream end of the aerosol-generating article is less than or equal to 30 millimetres.

[0230] Example EX22: An aerosol-generating article according to any one of examples EX16 to EX21, wherein a distance between the ventilation zone and an upstream end of the aerosolgenerating article is at least 20 millimetres.

[0231] Example EX23: An aerosol-generating article according to any one of examples EX16 to EX21, wherein a distance between the ventilation zone and an upstream end of the aerosolgenerating article is at least 25 millimetres.

[0232] Example EX24: An aerosol-generating article according to any one of examples EX16 to EX23, wherein a distance between the ventilation zone and a downstream end of the aerosolgenerating article is less than or equal to 25 millimetres.

[0233] Example EX25: An aerosol-generating article according to any one of examples EX16 to EX23, wherein a distance between the ventilation zone and a downstream end of the aerosolgenerating article is less than or equal to 20 millimetres.

[0234] Example EX26: An aerosol-generating article according to any one of examples EX16 to EX25, wherein a distance between the ventilation zone and a downstream end of the aerosolgenerating article is at least 10 millimetres.

[0235] Example EX27: An aerosol-generating article according to any one of examples EX16 to EX25, wherein a distance between the ventilation zone and a downstream end of the aerosolgenerating article is at least 12 millimetres.

[0236] Example EX28: An aerosol-generating article according to any one of examples EX16 to EX25, wherein a distance between the ventilation zone and a downstream end of the aerosolgenerating article is at least 14 millimetres.Example EX29: An aerosol-generating article according to any one of examples EX16 to EX25, wherein a distance between the ventilation zone and a downstream end of the aerosolgenerating article is at least 16 millimetres.

[0237] Example EX30. An aerosol-generating article according to any one of examples EX1 to EX29, wherein a ratio between a thickness of the wrapper and a diameter of the rod is at least 0.014.

[0238] Example EX31. An aerosol-generating article according to any one of examples EX1 to EX29, wherein a ratio between a thickness of the wrapper and a diameter of the rod is at least 0.016.

[0239] Example EX32: An aerosol-generating article according to any one of examples EX1 to EX29, wherein a ratio between a thickness of the wrapper and a diameter of the rod is at least 0.018.

[0240] Example EX34: An aerosol-generating article according to any one of examples EX1 to EX32, wherein a ratio between a thickness of the wrapper and a diameter of the rod is less than or equal to 0.167.

[0241] Example EX35: An aerosol-generating article according to any one of examples EX1 to EX32, wherein a ratio between a thickness of the wrapper and a diameter of the rod is less than or equal to 0.15.

[0242] Example EX36: An aerosol-generating article according to any one of examples EX1 to EX32, wherein a ratio between a thickness of the wrapper and a diameter of the rod is less than or equal to 0.1.

[0243] Example EX37: An aerosol-generating article according to any one of examples EX1 to EX32, wherein a ratio between a thickness of the wrapper and a diameter of the rod is less than or equal to 0.05.

[0244] Example EX38: An aerosol-generating article according to any one of examples EX1 to EX37, further comprising a band of tipping paper circumscribing the wrapper and extending longitudinally from a downstream end of the article to a location along the cavity.

[0245] Example EX 39: An aerosol-generating article according to any one of examples EX1 to EX37, further comprising indicia applied on a region of an outer surface of the wrapper, the region extending longitudinally from a downstream end of the article to a location along the cavity.

[0246] Example EX40: An aerosol-generating article according to any one of examples EX1 to EX39, further comprising an intermediate element in longitudinal arrangement with the rod and the mouthpiece segment, the intermediate element provided between the rod and the mouthpiece segment so that the cavity extends longitudinally all the way to a downstream end of the intermediate element.

[0247] Example EX41: An aerosol-generating article according to example EX40, wherein the intermediate element comprises a plug of filtration material.Example EX42: An aerosol-generating article according to example EX40, wherein the intermediate element comprises a hollow plug of filtration material, an internal diameter of the hollow plug being smaller than a diameter of the cavity.

[0248] Example EX43: An aerosol-generating system comprising: an aerosol-generating article according to any one of examples EX1 to EX42; and an aerosol-generating device configured to supply heat to the aerosol-generating substrate.

[0249] Example EX44: An aerosol-generating article for producing an inhalable aerosol upon heating, the aerosol-generating article comprising a rod of aerosol-generating substrate comprising an aerosol former; a mouthpiece segment arranged downstream of the rod and in longitudinal alignment with the rod; and a wrapper circumscribing the rod and the mouthpiece segment, the wrapper forming a peripheral wall of a hollow tubular segment defining a cavity in longitudinal alignment with the rod and the mouthpiece segment.

[0250] Example EX45: An aerosol-generating article according to example EX44, wherein an outer surface of the wrapper forms at least part of an outer surface of the aerosol-generating article.

[0251] Example EX46: An aerosol-generating article according to example EX44, wherein an outer surface of the wrapper forms an outer surface of the aerosol-generating article over the entire length of the cavity.

[0252] Example EX47: An aerosol-generating article according to example EX44, wherein an outer surface of the wrapper forms an outer surface of the aerosol-generating article over the entire length of the aerosol-generating article.

[0253] Example EX48: An aerosol-generating article according to any one of examples EX44 to EX47, wherein the cavity extends longitudinally all the way to the mouthpiece segment and radially all the way to the wrapper.

[0254] Example EX49: An aerosol-generating article according to any one of examples EX44 to EX48, wherein the aerosol-generating article further comprises an upstream element provided upstream of the rod, in longitudinal alignment with the rod and abutting an upstream end of the rod, and wherein the wrapper further circumscribes the upstream element.

[0255] The invention will be further described, by way of example only, with reference to the accompanying drawings in which:

[0256] Figure 1 is a schematic sectional view of an aerosol-generating article according to the present invention; and

[0257] Figure 2 is a schematic, enlarged sectional view taken along the plane A1-A1 of Figure 1.

[0258] An example of an aerosol-generating article 100 in accordance with the present invention is illustrated in Figures 1 and 2.The aerosol-generating article 100 comprises: an upstream element 10, a rod 12 of aerosol-generating substrate, and a mouthpiece segment 14. These three elements are arranged in longitudinal alignment and are circumscribed by a wrapper 16. Thus, the aerosol-generating article 100 extends from a mouth end 18 to an upstream, distal end 20 located at the opposite end of the article to the mouth end 18.

[0259] The wrapper 16 forms a peripheral wall 22 of a hollow tubular segment 24 defining a cavity 26 in longitudinal alignment with the rod 12 and the mouthpiece segment 14, so that the cavity 26 is arranged between the rod 12 and the mouthpiece segment 14.

[0260] The cavity 26 extends radially all the way to the wrapper 16. The cavity 26 extends longitudinally all the way to the mouthpiece segment 14. In more detail, the cavity 26 extends longitudinally from the rod 12 to the mouthpiece segment 14. More precisely, the cavity 26 extends from a downstream end of the rod 12 to an upstream end of the mouthpiece segment 14.

[0261] The aerosol-generating article 100 further comprises a band of tipping paper 28 that circumscribes a portion of the wrapper 16. A length of the band of tipping paper 28 is less than a length of the wrapper 16, and the band of tipping paper 28 extends from the mouth end 18 of the aerosol-generating article 10 to an intermediate location 30 comprised between the mouth end 18 and the distal end 20 of the aerosol-generating article 100. As such, the band of tipping paper 28 extends over the entire length of the mouthpiece segment 14 and over part of the length of the hollow tubular segment 24.

[0262] Additionally, the aerosol-generating article 100 comprises a ventilation zone 32 comprising a row of perforations arranged about a circumference of the aerosol-generating article 100. The perforations are formed through both the band of tipping paper 28 and the wrapper 16, so as to establish fluid communication between the cavity 26 and the exterior of the aerosol-generating article 100.

[0263] The upstream element 10 comprises a plug of filter material circumscribed by an individual plug wrap. Similarly, the mouthpiece segment 14 comprises a plug of filter material circumscribed by an individual plug wrap. The rod 12 of aerosol-generating substrate comprises tobacco cut filler.

[0264] The upstream element 10 has a length of from 5 millimetres to 6 millimetres and a diameter of from 6.95 millimetres to 7.05 millimetres. The rod 12 of aerosol-generating substrate has a length of from 8 millimetres to 14 millimetres and a diameter of from 6.95 millimetres to 7.05 millimetres. The mouthpiece segment 14 has a length of from 6.5 millimetres to 7.5 millimetres and a diameter of from 6.5 millimetres to 7.5 millimetres.

[0265] The cavity 26 has a length of from 20 millimetres to 22 millimetres and a diameter of from 6.95 millimetres to 7.05 millimetres.The wrapper 16 has a thickness of from 0.10 millimetres to 0.14 millimetres. The band of tipping paper 28 has a thickness of from 0.02 millimetres to 0.04 millimetres, and a length of from 19 millimetres to 21 millimetres.

[0266] The aerosol-generating article 100 shown in Figure 1 is particularly suitable for use with an electrically operated aerosol-generating device comprising a heater for heating the aerosolgenerating substrate in the rod 12.

[0267] For the purpose of the present description and of the appended claims, except where otherwise indicated, all numbers expressing amounts, quantities, percentages, and so forth, are to be understood as being modified in all instances by the term "about". Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein. In this context, therefore, a number A is understood as A ± 10 percent of A. Within this context, a number A may be considered to include numerical values that are within general standard error for the measurement of the property that the number A modifies. The number A, in some instances as used in the appended claims, may deviate by the percentages enumerated above provided that the amount by which A deviates does not materially affect the basic and novel characteristic(s) of the claimed invention. Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein.

Claims

CLAIMS1. An aerosol-generating article for producing an inhalable aerosol upon heating, the aerosol-generating article comprising:a rod of aerosol-generating substrate comprising an aerosol former;an upstream element provided upstream of the rod, in longitudinal alignment with the rod and abutting an upstream end of the rod;a mouthpiece segment arranged downstream of the rod and in longitudinal alignment with the rod;a wrapper circumscribing the rod and the mouthpiece segment, the wrapper forming a peripheral wall of a hollow tubular segment defining a cavity in longitudinal alignment with the rod and the mouthpiece segment, the cavity arranged between the rod and the mouthpiece segment; wherein the cavity extends longitudinally all the way to the mouthpiece segment and radially all the way to the wrapper, andwherein a length of the cavity is at least 15 millimetres.

2. An aerosol-generating article according to claim 1, wherein the wrapper further circumscribes the upstream element and wherein the upstream element and the wrapper extend all the way to an upstream end of the aerosol-generating article.

3. An aerosol-generating article according to claim 1 or 2, wherein the wrapper has a thickness of at least 100 micrometres.

4. An aerosol-generating article according to any one of claims 1 to 3, wherein the wrapper has a thickness of less than or equal to 500 micrometres.

5. An aerosol-generating article according to any one of claims 1 to 4, wherein a the wrapper has a basis weight of at least 70 gsm.

6. An aerosol-generating article according to any one of claims 1 to 5, wherein a the wrapper has a basis weight of less than or equal to 120 gsm.

7. An aerosol-generating article according to any one of claims 1 to 6 further comprising a ventilation zone to enable air to flow into the cavity from an exterior of the aerosol-generating article.

8. An aerosol-generating article according to claim 7, wherein the ventilation zone comprises a row of ventilation perforations formed through the wrapper and arranged circumferentially about a longitudinal axis of the aerosol-generating article.

9. An aerosol-generating article according to claim 7 or 8, wherein a distance between the ventilation zone and an upstream end of the aerosol-generating article is less than or equal to 45 millimetres.

10. An aerosol-generating article according to any one of claims 7 to 9, wherein a distance between the ventilation zone and an upstream end of the aerosol-generating article is at least 20 millimetres.

11. An aerosol-generating article according to any one of claims 1 to 10, wherein a ratio between a thickness of the wrapper and a diameter of the rod is at least 0.014.

12. An aerosol-generating article according to any one of claims 1 to 11, wherein a ratio between a thickness of the wrapper and a diameter of the rod is less than or equal to 0.167.

13. An aerosol-generating article according to any one of claims 1 to 12, further comprising a band of tipping paper circumscribing the wrapper and extending longitudinally from a downstream end of the article to a location along the cavity.

14. An aerosol-generating article according to any one of claims 1 to 13, further comprising an intermediate element in longitudinal arrangement with the rod and the mouthpiece segment, the intermediate element provided between the rod and the mouthpiece segment so that the cavity extends longitudinally all the way to a downstream end of the intermediate element.

15. An aerosol-generating system comprising:an aerosol-generating article according to any one of claims 1 to 14; andan aerosol-generating device configured to supply heat to the aerosol-generating substrate.

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