RU2843434C2 - Aerosol-generating article with segments in the form of a plug, adjacent on the sides to the aerosol-generating element - Google Patents

Abstract

FIELD: aerosol-generating articles.

SUBSTANCE: aerosol-generating article (1) is provided for producing an inhalable aerosol when heated. Aerosol-generating article comprises first segment (2) in the form of a plug, second segment (6) in the form of a plug, aerosol-generating member (4), and wrap (8). Second segment in form of plug is permeable. Aerosol-generating element is located directly between the first segment in the form of a plug and the second segment in the form of a plug. Second segment in the form of a plug is placed further downstream of the aerosol-generating element. Wrapper surrounds first segment in form of plug, element, generating aerosol, and second segment in form of plug. Wrapper part (12) surrounding the aerosol-generating element is air-permeable so that the wrapper provides fluid communication between the outer part of the aerosol-generating article and the aerosol-generating element.

EFFECT: aerosol-generating article is disclosed.

15 cl, 5 dwg

Description

The present invention relates to an aerosol generating article comprising an aerosol generating substrate and adapted to produce an inhalable aerosol upon heating.

Aerosol-generating articles in which an aerosol-generating substrate, such as a tobacco-containing substrate, is heated rather than burned are known in the art. Typically, in such heated smoking articles, the aerosol is generated by heat transfer from a heat source to a physically separate aerosol-generating substrate or material, which may be placed 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.

In a number of prior art documents, aerosol generating devices for consuming aerosol generating articles are disclosed. Such devices include, for example, electrically heated aerosol generating devices, in which the aerosol is generated by transferring heat from one or more electrical heating elements of the aerosol generating device to an aerosol generating substrate of the heated aerosol generating article. For example, electrically heated aerosol generating devices have been proposed, which comprise an internal heating plate, which is adapted to be inserted into an aerosol generating substrate. As an alternative, inductively heated aerosol generating articles have been proposed in WO 2015/176898, comprising an aerosol generating substrate and a current collector, which is located inside the aerosol generating substrate. A further alternative embodiment has been described in document WO 2020/115151, which discloses an aerosol generating article used in combination with an external heating system comprising one or more heating elements located around the periphery of the aerosol generating article. For example, the external heating elements may be provided in the form of flexible heating foils on a dielectric substrate, such as polyimide.

Aerosol generating articles in which an aerosol forming (or aerosol generating) substrate, such as a tobacco containing substrate, is heated rather than burned, pose a number of problems that have not been encountered with conventional smoking articles. Existing articles are intended for use in devices having heaters that are configured to heat an aerosol forming substrate externally and to draw air preferentially through the aerosol forming substrate in an axial or longitudinal direction. However, the inventors of the present invention have found that it may be highly advantageous to provide flexibility in controlling the combination of air intake into the article in the axial and radial directions, potentially resulting in improved aerosol delivery to the end user when the article is used with an external heating or aerosol generating device. In particular, in the context of external heaters surrounding at least a portion of an aerosol-generating substrate, when the article is located inside the aerosol-generating device, it is advantageous to design the article in such a way that air can at least enter the article through the outer portion of the heated substrate, instead of or in addition to air entering the article through an upstream end.

It would also be advantageous to provide one such aerosol-generating rod or one such aerosol-generating article that can be manufactured efficiently and at high speed without the need for significant modification of existing equipment. It would also be advantageous to provide a new and improved aerosol-generating rod or article that is capable of more quickly providing satisfactory delivery of aerosol to the user and providing more precise control of aerosol delivery during use overall. It would be especially advantageous to provide one such new and improved aerosol-generating rod or one such aerosol-generating article that can generate satisfactory delivery of aerosol to the user at lower temperatures while still heating the tobacco-containing substrate for regular consumption.

The present invention relates to an aerosol-generating rod or article for producing an inhalable aerosol upon heating. The aerosol-generating rod or article may comprise a first segment. The aerosol-generating rod or article may comprise a second segment. The aerosol-generating rod or article may comprise an aerosol-generating element. The aerosol-generating rod or article may comprise a wrapper. The second segment may be permeable, preferably air-permeable. The aerosol-generating element may be located between the first segment and the second segment. The second segment may be located downstream of the aerosol-generating element. The wrapper may surround the first segment, the aerosol-generating element, and the second segment. A portion of the wrapper surrounding the aerosol generating element may be breathable such that the wrapper provides fluid communication between the outer portion of the aerosol generating article and the aerosol generating element.

The first segment may be the first stub segment. The second segment may be the second stub segment. The first segment may also be called the upstream segment. The second segment may also be called the downstream segment.

The aerosol generating element may be located downstream of the first segment. The aerosol generating element may be located immediately downstream of the first element. The second segment may be located immediately downstream of the aerosol generating element. The aerosol generating element may be located directly between the first segment and the second segment. The first segment in the form of a plug may be adjacent to the aerosol generating element. The second segment in the form of a plug may be adjacent to the aerosol generating element. The first segment in the form of a plug, the element (or substrate) generating the aerosol, and the second segment in the form of a plug may be in axial alignment with each other. The first segment in the form of a plug, the element (or substrate) generating the aerosol, and the second segment in the form of a plug may be arranged in series.

According to the present invention, an aerosol generating article or rod is provided for producing an inhalable aerosol upon heating. The aerosol generating article or rod comprises a first segment in the form of a plug, a second segment in the form of a plug, an aerosol generating element, and a wrapper. The second segment in the form of a plug is permeable, preferably air-permeable. The aerosol generating element is located directly between the first segment (the segment in the form of a plug) and the second segment (the segment in the form of a plug). The second segment in the form of a plug is located further downstream of the aerosol generating element. The wrapper surrounds the first segment in the form of a plug, the aerosol generating element, and the second segment in the form of a plug. A portion of the wrapper surrounding the aerosol generating element is breathable such that the wrapper provides fluid communication between the outer portion of the aerosol generating article or rod and the aerosol generating element.

The present invention and disclosure provide a new and compact configuration of an aerosol generating rod or article that allows flexible control of air intake into an aerosol generating element. By providing two plug segments on each side of the aerosol generating element and a wrapper that is air permeable (or porous) at least where it overlaps the aerosol generating element, the amount of air entering the aerosol generating element from the axial direction through the upstream plug segment and from the radial or transverse direction through the air permeable portion of the wrapper can be easily controlled by adjusting the permeability characteristics of the first upstream plug segment and the wrapper. The presence of the aerosol generating element directly between the first and second plug segments further ensures that the permeability characteristics of the plug segments significantly affect the delivery of the aerosol to the user.

By at least establishing fluid communication between the exterior of the article and the aerosol generating element through a breathable wrapper, it is ensured that air flows directly into the aerosol generating element without having to flow through any other components located upstream of the article and the aerosol generating element. In the context of external heating devices, air flowing directly into the aerosol generating element will be partially heated as it flows through or past the external heater. This will essentially allow for faster and more efficient heating of the aerosol generating element, since air entering through the wrapper is more likely to be warmer than air entering the upstream end of the article in a substantially axial direction, thereby reducing any initial delay in aerosol generation and delivery that is found in existing aerosol generating articles and systems when the user begins consumption.

In addition, the provision of two segments adjacent laterally on each side of the aerosol generating element ensures that any waste or segments of the aerosol generating element are prevented from escaping from either side of the aerosol generating article. This advantage is further enhanced by the provision of segments immediately adjacent laterally on each side of the aerosol generating element, as this ensures that the contents of the aerosol generating element remain in their original position and cannot migrate to other locations in the article or leave the article or rod.

According to the present invention, an aerosol generating rod or article is provided for producing an inhalable aerosol upon heating. The aerosol generating article or rod may comprise a first segment in the form of a plug, a second segment in the form of a plug, an aerosol generating element, and a wrapper. The second segment in the form of a plug may be permeable. The aerosol generating element may be located directly between the first segment (the segment in the form of a plug) and the second segment (the segment in the form of a plug). The second segment in the form of a plug may be located further downstream of the aerosol generating element. The wrapper may surround the first segment in the form of a plug, the aerosol generating element, and the second segment in the form of a plug. A portion of the wrapper surrounding the aerosol generating element may be breathable. The air permeability of the permeable portion of the wrapper may be at least approximately 2500 Coresta units. The air permeability of the permeable portion of the wrapper may be at least approximately 5000 Coresta units.

The term "aerosol-generating article" is used in this document to refer to an article in which an aerosol-generating substrate is heated to produce and deliver an inhalable aerosol to a user. As used in this document, the term "aerosol-generating substrate" refers to a substrate capable of releasing volatile compounds when heated to generate an aerosol.

A conventional cigarette is lit when the user applies a flame to one end of the cigarette and draws air through the other end. The localized heat provided by the flame and the oxygen in the air drawn through the cigarette causes the end of the cigarette to ignite, and the resulting combustion generates inhaled smoke. In contrast, in heated aerosol-generating articles, the aerosol is generated by heating a flavor-generating substrate, such as tobacco. Known heated aerosol-generating articles include, for example, electrically heated aerosol-generating articles and aerosol-generating articles in which the aerosol is generated by transferring heat from a combustible heat-generating element or heat source to a physically separate aerosol-forming material. For example, the aerosol generating articles according to the present invention find particular application in aerosol generating systems comprising an electrically heated aerosol generating device having an internal heating plate which is adapted to be inserted into a rod of a substrate generating an aerosol. Aerosol generating articles of this type are described in the prior art, for example in document EP 0 822 670.

As used herein, the term "aerosol generating device" refers to a device that includes a heater or heating element that interacts with an aerosol generating (or aerosol forming) substrate of an aerosol generating article to generate an aerosol.

In the context of this document, with reference to the present invention, the term "rod" is used to designate a generally elongated element, preferably a cylindrical element of a substantially circular, oval or elliptical cross-section. The aerosol-generating article according to the present invention may also be referred to throughout the present description as an aerosol-generating rod. The aerosol-generating article according to the present invention may comprise an aerosol-generating rod and a downstream section located downstream of the rod. The downstream section may also be referred to as a "filter" of the aerosol-generating article. In the present disclosure, the term "aerosol-generating rod" refers to a portion of the article comprising or consisting of an aerosol-generating element and two laterally adjacent segments (in the form of a plug).

In the context of this document, the term "longitudinal" refers to the direction corresponding to the major longitudinal axis of the aerosol-generating article that extends between the upstream and downstream ends of the aerosol-generating article. In the context of this document, the terms "upstream" and "downstream" describe the relative positions of elements or portions of elements of the aerosol-generating article with respect to the direction in which the aerosol is transported through the aerosol-generating article during use.

During use, air is drawn through the aerosol-generating article in the longitudinal direction. The term "cross" refers to the direction that is perpendicular to the longitudinal axis. Any reference to a "section" of the aerosol-generating article or a component of the aerosol-generating article refers to the cross-section unless otherwise specified.

The term "length" refers to the longitudinal dimension of a component of an aerosol-generating article. For example, it can be used to refer to the longitudinal dimension of a rod or elongated tubular elements.

As mentioned above, the aerosol generating article may further comprise a downstream section at a location downstream of the aerosol generating rod. The downstream section may comprise one or more downstream elements.

The downstream section may comprise a hollow section between the mouth end of the aerosol generating article and the aerosol generating rod. The hollow section may comprise a hollow tubular member.

In the context of this document, terms such as "hollow tubular segment" and "hollow tubular element" are used to designate a generally elongated element that defines a lumen or passage for air flow along its longitudinal axis. In particular, the term "tubular" will be used hereinafter with reference to an element or segment that has a substantially cylindrical cross-section and defines at least one air flow channel that establishes continuous fluid communication between an upstream end of the tubular element or segment and a downstream end of the tubular element or segment. However, it should be understood that alternative geometric parameters (e.g., alternative cross-sectional shapes) of the tubular element or segment may be possible.

The term "immediate" or "directly" preferably refers to two components adjacent to each other without space or gaps between them.

In the context of the present invention, the hollow tubular segment or the hollow tubular element provides an unrestricted flow channel. This means that the hollow tubular segment or the hollow tubular element provides an insignificant level of resistance to draw (RTD). The term "insignificant level of RTD" is used to describe an RTD of less than 1 mm H2O per 10 millimeters of the length of the hollow tubular segment or the hollow tubular element, preferably less than 0.4 mm H2O per 10 millimeters of the length of the hollow tubular segment or the hollow tubular element, more preferably less than 0.1 mm H2O per 10 millimeters of the length of the hollow tubular segment or the hollow tubular element.

Therefore, the flow channel must be free of any components that would impede the longitudinal flow of air. Preferably, the flow channel is substantially empty.

In the present description, a "hollow tubular segment" or "hollow tubular element" may also be referred to as a "hollow tube" or a "hollow tube-shaped segment".

The aerosol generating article may further comprise an upstream section at a location upstream of the aerosol generating rod. The upstream section may comprise one or more upstream elements. The upstream section may comprise an upstream element located immediately upstream of the aerosol generating rod; i.e., immediately upstream of the first plug segment.

The aerosol generating rod or article according to the present invention may be substantially cylindrical and may have an outer diameter of at least about 4 millimeters. More preferably, the aerosol generating rod has an outer diameter of at least about 5 millimeters. Even more preferably, the aerosol generating rod has an outer diameter of at least about 6 millimeters.

The aerosol generating rod preferably has an outer diameter that is less than or equal to approximately 12 millimeters. More preferably, the aerosol generating rod has an outer diameter that is less than or equal to approximately 11 millimeters. Even more preferably, the aerosol generating rod has an outer diameter that is less than or equal to approximately 8 millimeters.

The aerosol generating rod may have an outer diameter of about 4 millimeters to about 12 millimeters, preferably 5 millimeters to about 12 millimeters, more preferably 6 millimeters to about 12 millimeters. The aerosol generating rod may have an outer diameter of about 4 millimeters to about 11 millimeters, preferably 5 millimeters to about 11 millimeters, more preferably 6 millimeters to about 11 millimeters. The aerosol generating rod may have an outer diameter of about 4 millimeters to about 8 millimeters, preferably 5 millimeters to about 8 millimeters, more preferably 6 millimeters to about 8 millimeters.

In general, it has been observed that the smaller the diameter of the rod-shaped element containing the aerosol-generating substrate, the lower the temperature required to raise the temperature of the core of the rod-shaped element so that sufficient amounts of the evaporable components are released from the aerosol-generating substrate to form the required amount of aerosol. At the same time, without being limited by theory, it is understood that a smaller diameter of the rod-shaped element allows a faster penetration of the heat supplied to the aerosol-generating rod into its entire volume. However, when the diameter of the rod-shaped element is too small, the volume-to-surface ratio of the aerosol-generating substrate becomes less favorable since the amount of available aerosol-forming substrate decreases. This is especially important for aerosol-generating articles designed to be heated by an external heater.

The diameter of the aerosol generating rod falling within the ranges described in this document is particularly advantageous in terms of the balance between energy consumption and aerosol delivery. This advantage is felt in particular when the aerosol generating article comprising an aerosol generating rod having a diameter as described in this document is used in combination with an external heater located around the periphery of the aerosol generating rod or article. It has been observed that under such operating conditions, less thermal energy is required to achieve a sufficiently high temperature in the core of the aerosol generating rod or in the core of the article comprising this rod. Thus, when operating at lower temperatures, the desired target temperature in the core of the aerosol generating rod can be achieved within the desired reduced time frame and by means of lower energy consumption.

The total length of the aerosol generating rod may be at least about 8 millimeters. Preferably, the total length of the aerosol generating rod is at least about 9 millimeters. More preferably, the total length of the aerosol generating rod is at least about 10 millimeters.

The total length of the aerosol generating rod is preferably less than or equal to about 27 millimeters. More preferably, the total length of the aerosol generating rod is preferably less than or equal to about 23 millimeters. Even more preferably, the total length of the aerosol generating rod is preferably less than or equal to about 19 millimeters.

The total length of the aerosol generating rod may be from about 8 millimeters to about 27 millimeters, preferably from about 9 millimeters to about 27 millimeters, more preferably from about 10 millimeters to about 27 millimeters. The total length of the aerosol generating rod may be from about 8 millimeters to about 23 millimeters, preferably from about 9 millimeters to about 23 millimeters, more preferably from about 10 millimeters to about 23 millimeters. The total length of the aerosol generating rod may be from about 8 millimeters to about 19 millimeters, preferably from about 9 millimeters to about 19 millimeters, more preferably from about 10 millimeters to about 19 millimeters.

The plug segments according to the present invention may have the same outer diameter as the outer diameter of the aerosol generating element. Preferably, the plug segment comprises a solid cross-section of material. In other words, the plug segment does not form any cavities, gaps or voids other than those already defined by the properties of the material itself, such as pores. This ensures that the plug segments prevent the unintentional release of the aerosol generating element material from the article.

The plug segment may have one or more openings or through-holes formed along the length of the plug segment. The number and arrangement of the openings or through-holes may depend on the nature of the aerosol generating element. Provision of such openings ensures that the resistance to draw (RTD) of the article is advantageously low. Either or both of the first and second plug segments may comprise such openings or through-holes. Each such opening may form a cavity within the plug segment. The plug segment may be a hollow tubular segment, preferably having a relatively thick wall.

The first upstream segment in the form of a plug may be substantially impermeable. The first segment in the form of a plug may be substantially air-impermeable, so that air cannot pass through the material of the first segment in the form of a plug and into the element or segment generating an aerosol. The material of the first upstream segment in the form of a plug may be substantially impermeable. As a result, air cannot flow into the rod or article generating an aerosol through its upstream end and can mainly enter the article generating an aerosol through the permeable or porous part or section of the wrapper.

The first upstream plug segment may be substantially permeable. The material of the first upstream plug segment may be substantially permeable. The first plug segment may be substantially air-permeable (or porous), so that air may pass through the material of the first plug segment and into the aerosol-generating element or segment. As a result, air may flow into the aerosol-generating rod or article through its upstream end and may also enter the aerosol-generating article through the permeable or porous portion or section of the wrapper.

Unless otherwise specified, the resistance to draw (RTD) of an aerosol-generating component or article or rod may be measured in accordance with ISO 6565-2015. RTD refers to the pressure required to force air through the entire length of the component. The terms "pressure drop" or "resistance to draw" of a component or article may also refer to "resistance to draw". Such terms generally refer to measurements in accordance with ISO 6565-2015, which are typically performed under test conditions at a volumetric flow rate of approximately 17.5 millilitres per second at the outlet or downstream end of the component being measured, at a temperature of approximately 22 degrees Celsius, a pressure of approximately 101 kPa (approximately 760 Torr) and a relative humidity of approximately 60%.

The resistance to draw per unit length of a specific component (or element) of an aerosol-generating article, such as a first plug segment, an aerosol-generating element, or a second plug segment, can be calculated by dividing the measured resistance to draw of the component by the total axial length of the component. The RTD per unit length refers to the pressure required to move air through a unit length of the component. Throughout this specification, a unit length refers to a length of 1 mm. Accordingly, to obtain the RTD per unit length of a specific component, a sample of a specific length, such as 15 mm, of the component can be used in the measurement. The RTD of such a sample is measured in accordance with ISO 6565-2015. If, for example, the measured RTD is approximately 15 mm H2O, then the RTD per unit length of the component is approximately 1 mm H2O per mm. The RTD per unit length of a component depends on the structural properties of the material used for the component, as well as the geometric shape or cross-sectional profile of the component, among other factors.

The relative RTD, or RTD per unit length, of the first plug segment or the second plug segment can be from about 0 mmH2O per mm to about 3 mmH2O per mm. The RTD per unit length of the first plug segment or the second plug segment can be from about 0 mmH2O per mm to about 2.5 mmH2O per mm. The RTD per unit length of the first plug segment or the second plug segment can be from about 0 mmH2O per mm to about 2 mmH2O per mm. The RTD per unit length of the first plug segment or the second plug segment can be from about 0 mmH2O per mm to about 1 mmH2O per mm. The RTD per unit length of the first plug segment or the second plug segment can be from about 0 mmH2O per mm per mm to approximately 0.75 mm H2O per mm.

As mentioned above, the relative RTD, or RTD per unit length, of the first plug segment or the second plug segment can be greater than about 0 mm H2O per mm and less than about 3 mm H2O per mm. The RTD per unit length of the first plug segment or the second plug segment can be greater than about 0 mm H2O per mm and less than about 2.5 mm H2O per mm. The RTD per unit length of the first plug segment or the second plug segment can be greater than about 0 mm H2O per mm and less than about 2 mm H2O per mm. The RTD per unit length of the first plug segment or the second plug segment can be greater than about 0 mm H2O per mm and less than about 1 mm H2O per mm. The RTD per unit length of the first plug segment or the second plug segment may be greater than approximately 0 mm H2O per mm and less than approximately 0.75 mm H2O per mm.

The RTD per unit length of the first plug segment or the second plug segment may be greater than or equal to about 0 mm H2O per mm. Thus, the RTD per unit length of the first plug segment or the second plug segment may be from about 0 mm H2O per mm to about 3 mm H2O per mm. The RTD per unit length of the first plug segment or the second plug segment may be from about 0 mm H2O per mm to about 2.5 mm H2O per mm. The RTD per unit length of the first plug segment or the second plug segment may be from about 0 mm H2O per mm to about 2 mm H2O per mm. The RTD per unit length of the first plug segment or the second plug segment may be from about 0 mm H2O per mm to about 1 mm H2O per mm. The RTD per unit length of the first plug segment or the second plug segment may be from approximately 0 mm H2O per mm to approximately 0.75 mm H2O per mm.

The tightening resistance of the first plug segment or the second plug segment may be greater than or equal to approximately 0 mm H2O and less than approximately 10 mm H2O. The tightening resistance of the first plug segment or the second plug segment may be greater than 0 mm H2O and less than approximately 5 mm H2O. The tightening resistance of the first plug segment or the second plug segment may be greater than 0 mm H2O and less than approximately 2 mm H2O. The tightening resistance of the first plug segment or the second plug segment may be greater than 0 mm H2O and less than approximately 1 mm H2O.

The RTD properties of the first plug segment and the second plug segment may be the same. The RTD properties of the first plug segment and the second plug segment may be different. For example, if they are different, the RTD (or RTD per unit length) of the second plug segment is preferably lower than the RTD (or RTD per unit length) of the first plug segment. Thus, the second plug segment performs the function of providing a barrier to prevent the displacement of the aerosol generating element material, without significantly increasing the RTD of the article.

The outer diameter of the first plug segment may be substantially the same as the outer diameter of the rod.

The first segment in the form of a plug may have a length of at least about 2 millimeters. Preferably, the first segment in the form of a plug has a length of at least about 3 millimeters. More preferably, the first segment in the form of a plug has a length of at least about 4 millimeters.

The first segment in the form of a plug may have a length of up to approximately 10 millimeters. Preferably, the first segment in the form of a plug has a length that is less than or equal to approximately 7 millimeters. More preferably, the first segment in the form of a plug has a length that is less than or equal to approximately 5 millimeters.

The first segment in the form of a plug can have a length of from about 2 millimeters to about 10 millimeters, preferably from about 3 millimeters to about 10 millimeters, more preferably from about 4 millimeters to about 10 millimeters. The first segment in the form of a plug can have a length of from about 2 millimeters to about 17 millimeters, preferably from about 3 millimeters to about 7 millimeters, more preferably from about 4 millimeters to about 7 millimeters. The first segment in the form of a plug can have a length of from about 2 millimeters to about 5 millimeters, preferably from about 3 millimeters to about 5 millimeters, more preferably from about 4 millimeters to about 5 millimeters.

In the aerosol generating rod or article according to the present invention, the ratio between the length of the first segment in the form of a plug and the length of the aerosol generating element is at least about 0.15. Preferably, the ratio between the length of the first segment in the form of a plug and the length of the aerosol generating element is at least about 0.2. More preferably, the ratio between the length of the first segment in the form of a plug and the length of the aerosol generating element is at least about 0.3.

The ratio between the length of the first segment in the form of a plug and the length of the aerosol generating element is preferably less than or equal to approximately 0.5. More preferably, the ratio between the length of the first segment in the form of a plug and the length of the aerosol generating element is less than or equal to approximately 0.45. Even more preferably, the ratio between the length of the first segment in the form of a plug and the length of the aerosol generating element is less than or equal to approximately 0.4.

The ratio between the length of the first segment in the form of a plug and the length of the aerosol generating element may be from about 0.15 to about 0.5, preferably from about 0.2 to about 0.5, more preferably from about 0.3 to about 0.5. The ratio between the length of the first segment in the form of a plug and the length of the aerosol generating element may be from about 0.15 to about 0.45, preferably from about 0.2 to about 0.45, more preferably from about 0.3 to about 0.45. The ratio between the length of the first segment in the form of a plug and the length of the aerosol generating element may be from about 0.15 to about 0.4, preferably from about 0.2 to about 0.4, more preferably from about 0.3 to about 0.4.

The second downstream plug segment or the first upstream plug segment may comprise a plug of porous substrate. The porous substrate plug may be substantially free of any aerosol-generating compounds.

The first plug-shaped segment or the second plug-shaped segment may be formed from a fibrous material. The first plug-shaped segment or the second plug-shaped segment may be formed from a porous material. The first plug-shaped segment or the second plug-shaped segment may be formed from a material permeable to a fluid medium or air. The first plug-shaped segment or the second plug-shaped segment may be formed from a material impermeable to a fluid medium or air. The first plug-shaped segment or the second plug-shaped segment may be formed from a biodegradable material. The first plug-shaped segment or the second plug-shaped segment may be formed from a cellulose material, such as cellulose acetate. For example, the first plug segment or the second plug segment can be formed from a bundle of cellulose acetate fibers having a denier per fiber value of from about 10 to about 15. For example, the first plug segment or the second plug segment is formed from a relatively low density cellulose acetate tow, such as a cellulose acetate tow comprising fibers of about 12 denier per fiber, which can provide an RTD per unit length of from about 0.8 to about 2.5 mm H2O per mm.

The first plug segment or the second plug segment may be formed from a polylactic acid-based material. The first plug segment or the second plug segment may be formed from a bioplastic material, preferably a starch-based bioplastic material. The first plug segment or the second plug segment may be manufactured by injection molding or extrusion. Bioplastic-based materials are advantageous because they can provide structures of the first plug segment or the second plug segment that are simple and inexpensive to manufacture with a specific and complex cross-sectional profile, which may contain a plurality of relatively large air flow channels passing through the material of the first plug segment or the second plug segment, which provides suitable RTD characteristics.

The first segment in the form of a plug or the second segment in the form of a plug can be formed from a sheet of a suitable material that has been corrugated, pleated, gathered, woven or folded into an element that forms a plurality of channels extending in the longitudinal direction. Such a sheet of a suitable material can be formed from paper, cardboard and a polymer such as polylactic acid or any other cellulose-based material, paper-based material or bioplastic-based material. The cross-sectional profile of such a first segment in the form of a plug or the second segment in the form of a plug can show the channels as randomly oriented.

The first plug segment or the second plug segment may be formed by any other suitable method. For example, the first plug segment or the second plug segment may be formed from a bundle of longitudinally extending tubes. The longitudinally extending tubes may be formed from polylactic acid. The first plug segment or the second plug segment may be formed by extrusion, casting, lamination, injection or milling of a suitable material. Thus, it is preferable that there is a small pressure drop (or RTD) from the upstream end of the first plug segment or the second plug segment to the downstream end of the first plug segment or the second plug segment.

Advantageously, the plug-type segments support the aerosol-generating segment or element and can help prevent any aerosol-generating material, such as tobacco material, contained in the aerosol-generating segment from shifting. In addition, the plug-type segments contribute to the overall structural strength of the rod and facilitate its handling, especially during manufacture.

Preferably, the second (downstream) plug segment does not substantially contribute significantly to the overall RTD of the aerosol generating rod.

The outer diameter of the second plug segment may be substantially the same as the outer diameter of the rod. The outer diameter of the second plug segment may be substantially the same as the outer diameter of the first plug segment.

The second segment in the form of a plug may have a length of at least about 2 millimeters. Preferably, the second segment in the form of a plug has a length of at least about 3 millimeters. More preferably, the second segment in the form of a plug has a length of at least about 4 millimeters.

The second segment in the form of a plug may have a length of up to approximately 10 millimeters. Preferably, the second segment in the form of a plug has a length that is less than or equal to approximately 7 millimeters. More preferably, the second segment in the form of a plug has a length that is less than or equal to approximately 5 millimeters.

The second segment in the form of a plug can have a length of from about 2 millimeters to about 10 millimeters, preferably from about 3 millimeters to about 10 millimeters, more preferably from about 4 millimeters to about 10 millimeters. The second segment in the form of a plug can have a length of from about 2 millimeters to about 17 millimeters, preferably from about 3 millimeters to about 7 millimeters, more preferably from about 4 millimeters to about 7 millimeters. The second segment in the form of a plug can have a length of from about 2 millimeters to about 5 millimeters, preferably from about 3 millimeters to about 5 millimeters, more preferably from about 4 millimeters to about 5 millimeters.

The components of the aerosol generating rod, which will be described in more detail, are surrounded by a wrapper, which may be a paper wrapper or a non-paper wrapper. One such wrapper may also align or attach the components of the aerosol generating rod or article to each other.

Paper wrappers suitable for use in the present invention (or the arrangements according to the present disclosure) are known in the art and include, but are not limited to, cigarette papers and filter papers. Non-paper wrappers suitable for use in the present invention (or the arrangements according to the present disclosure) are known in the art and include, but are not limited to, sheets of homogenized tobacco materials.

As discussed above, the wrapper or wrapping material surrounds the first segment in the form of a plug, the aerosol generating element, and the second segment in the form of a plug. The wrapper comprises a substantially permeable section or part. The permeable section or part overlaps or covers at least a part of the aerosol generating element. The permeable section of the wrapper is configured to provide fluid communication between the outer part of the aerosol generating article and the aerosol generating element. The permeable section or part is preferably a substantially air-permeable section or part.

The permeable portion of the wrapper may partially or completely surround the outer perimeter or circumference of the aerosol generating element.

The permeable portion of the wrapper may cover at least about 10 percent of the outer surface of the aerosol-generating element. The permeable portion of the wrapper may cover at least about 20 percent of the outer surface of the aerosol-generating element. The permeable portion of the wrapper may cover at least about 25 percent of the outer surface of the aerosol-generating element. The permeable portion of the wrapper may cover at least about 40 percent of the outer surface of the aerosol-generating element. The permeable portion of the wrapper may cover at least about 50 percent of the outer surface of the aerosol-generating element. The permeable portion of the wrapper may cover at least about 60 percent of the outer surface of the aerosol-generating element. The permeable portion of the wrapper may cover at least about 75 percent of the outer surface of the aerosol-generating element. The permeable portion of the wrapper may cover at least approximately 80 percent of the outer surface of the aerosol generating element. Preferably, the permeable portion of the wrapper may cover or overlap the entire outer surface of the aerosol generating element.

Preferably, the entire permeable portion (or section) of the wrapper overlaps or covers the aerosol generating element. Preferably, the remainder of the wrapper is not permeable. Preferably, the portion or portions of the wrapper that do not overlap or cover the aerosol generating element are not permeable. Preferably, the wrapper comprises a permeable portion (or section) and an impermeable portion.

The length of the permeable portion of the wrapper may be at least approximately 10 percent of the length of the aerosol-generating element. The length of the permeable portion of the wrapper may be at least approximately 20 percent of the length of the aerosol-generating element. The length of the permeable portion of the wrapper may be at least approximately 25 percent of the length of the aerosol-generating element. The length of the permeable portion of the wrapper may be at least approximately 40 percent of the length of the aerosol-generating element. The length of the permeable portion of the wrapper may be at least approximately 50 percent of the length of the aerosol-generating element. The length of the permeable portion of the wrapper may be at least approximately 60 percent of the length of the aerosol-generating element. The length of the permeable portion of the wrapper may be at least approximately 75 percent of the length of the aerosol-generating element. The length of the permeable portion of the wrapper may be the same as the length of the wrapper itself. The length of the permeable portion of the wrapper may be at least approximately 80 percent of the length of the aerosol-generating element. Preferably, the length of the wrapper is the same as the length of the aerosol-generating rod or the aerosol-generating article.

The surface area of the permeable portion (or portion) of the wrapper may be at least approximately 10 percent of the outer surface of the aerosol-generating element. The surface area of the permeable portion of the wrapper may be at least approximately 20 percent of the outer surface of the aerosol-generating element. The surface area of the permeable portion of the wrapper may be at least approximately 25 percent of the outer surface of the aerosol-generating element. The surface area of the permeable portion of the wrapper may be at least approximately 40 percent of the outer surface of the aerosol-generating element. The surface area of the permeable portion of the wrapper may be at least approximately 50 percent of the outer surface of the aerosol-generating element. The surface area of the permeable portion of the wrapper may be at least approximately 60 percent of the outer surface of the aerosol-generating element. The surface area of the permeable portion of the wrapper may be at least approximately 75 percent of the outer surface of the aerosol-generating element. The surface area of the permeable portion of the wrapper may be at least approximately 80 percent of the outer surface of the aerosol generating element. The surface area of the permeable portion of the wrapper may be the same as the outer surface of the aerosol generating element. The surface area of the permeable portion of the wrapper may be the same as the surface area of the wrapper itself.

The permeable portion may extend around at least about 10 percent of the outer circumference or perimeter of the aerosol-generating element. The permeable portion may extend around at least about 25 percent of the outer circumference or perimeter of the aerosol-generating element. The permeable portion may extend around at least about 50 percent of the outer circumference or perimeter of the aerosol-generating element. The permeable portion may extend around at least about 75 percent of the outer circumference or perimeter of the aerosol-generating element. The permeable portion may extend around the entire outer circumference or perimeter of the aerosol-generating element. In other words, the permeable portion may completely surround the aerosol-generating element.

The inventors of the present invention have found that the dimensions of the permeable region or portion of the wrapper can be optimized for different articles in combination with a specific range of wrapper air permeability values, depending on the air flow requirements of the article and its aerosol-generating substrate. For example, for certain articles and aerosol-generating substrates, it may be advantageous to provide a wrapper with a relatively large permeable region (preferably in accordance with the present disclosure) to distribute the drawn air across the aerosol-generating substrate.

In some cases, it may be advantageous to provide a wrapper with a relatively small permeable area to concentrate the drawn air in a specific location around the aerosol generating element. This may be advantageous in ensuring compatibility between the aerosol generating article and the devices with which the article is adapted for use.

The term "outer surface" preferably refers to the outer surface of the element that extends in the longitudinal direction parallel to the longitudinal axis defined by the product. The term "outer surface" may refer to the "outer longitudinal surface".

The entire wrapper can be permeable (breathable).

The air permeability of the permeable portion of the wrapper, or wrapper, may be greater than approximately 2500 Coresta units. The air permeability of the permeable portion of the wrapper, or wrapper, may be greater than approximately 5000 Coresta units. The air permeability of the permeable portion of the wrapper, or wrapper, may be greater than approximately 7500 Coresta units.

The air permeability of the permeable portion of the wrapper, or wrapper, may be less than about 12,000 Coresta units. The air permeability of the permeable portion of the wrapper, or wrapper, may be less than about 11,000 Coresta units. The air permeability of the permeable portion of the wrapper, or wrapper, may be less than about 10,000 Coresta units.

The air permeability of the permeable portion of the wrapper or wrapper may be at least about 2500 Coresta units. The air permeability of the permeable portion of the wrapper or wrapper may be at least about 5000 Coresta units. The air permeability of the permeable portion of the wrapper or wrapper may be at least about 7500 Coresta units.

The air permeability of the permeable portion of the wrapper, or wrapper, may be approximately 12,000 Coresta units or less. The air permeability of the permeable portion of the wrapper, or wrapper, may be approximately 11,000 Coresta units or less. The air permeability of the permeable portion of the wrapper, or wrapper, may be approximately 10,000 Coresta units or less.

The air permeability of the permeable portion of the wrapper may be from about 2,500 Coresta units to about 12,000 Coresta units. The air permeability of the permeable portion of the wrapper may be from about 5,000 Coresta units to about 12,000 Coresta units. The air permeability of the permeable portion of the wrapper may be from about 7,500 Coresta units to about 12,000 Coresta units.

The air permeability of the permeable portion of the wrapper may be from about 2,500 Coresta units to about 11,000 Coresta units. The air permeability of the permeable portion of the wrapper may be from about 5,000 Coresta units to about 11,000 Coresta units. The air permeability of the permeable portion of the wrapper may be from about 7,500 Coresta units to about 11,000 Coresta units.

The air permeability of the permeable portion of the wrapper may be from about 2,500 Coresta units to about 10,000 Coresta units. The air permeability of the permeable portion of the wrapper may be from about 5,000 Coresta units to about 10,000 Coresta units. The air permeability of the permeable portion of the wrapper may be from about 7,500 Coresta units to about 10,000 Coresta units.

Air permeability in Coresta units is the amount of air in cubic centimetres that passes through one square centimetre of the wrapper in one minute under a constant pressure difference of one kilopascal (i.e. 1 Coresta unit corresponds to an air permeability of 1 ^cm3 / ^min⋅cm2 under a pressure difference of 1 kPa). Air permeability in Coresta units can be measured in accordance with ISO 2965:2009.

Providing a wrapper with a relatively high (air-) permeability advantageously ensures that the wrapper can allow a significant amount of air to enter the aerosol generating article to carry the generated aerosol to the user without requiring air to enter through an upstream end of the article or rod.

The basis weight of the wrapper may be at least about 10 grams per square meter (gsm or ^gsm2 ). The basis weight of the wrapper may be at least about 15 ^gsm .

The basis weight of the wrapper may be less than approximately 30 g/ ^m2 . The basis weight of the wrapper may be less than approximately 25 g/ ^m2 .

The basis weight of the wrapper may be from about 10 g/ ^m2 to about 30 g/ ^m2 . The basis weight of the wrapper may be from about 15 g/ ^m2 to about 25 g/ ^m2 .

The thickness of the wrapper may be at least about 0.01 mm. The thickness of the wrapper may be at least about 0.02 mm. The thickness of the wrapper may be at least about 0.03 mm.

The thickness of the wrapper may be less than approximately 0.1 mm. The thickness of the wrapper may be less than approximately 0.08 mm. The thickness of the wrapper may be less than approximately 0.07 mm.

The thickness of the wrapper may be from about 0.01 mm to about 0.1 mm. The thickness of the wrapper may be from about 0.02 mm to about 0.08 mm. The thickness of the wrapper may be from about 0.03 mm to about 0.07 mm.

Preferably, the aerosol generating element is visible through the wrapper. The aerosol generating element may be at least partially visible through the wrapper. The wrapper or at least a portion of the wrapper surrounding the aerosol generating element may be substantially translucent or substantially transparent. The permeable portion of the wrapper may be substantially translucent or substantially transparent.

The term "substantially transparent" is used herein to describe a material that allows at least a sufficient portion of incident light to pass through it so that it is possible to see through the material. In the present invention, a substantially transparent wrapper allows a sufficient amount of light to pass through it so that the underlying aerosol-generating element is visible through the wrapper. The transparency of a substantially transparent wrapper can be evaluated in accordance with ASTM D1003-13.

The wrapper may be completely transparent. The transparent portion of the wrapper may have a lower level of transparency, while still transmitting a sufficient amount of light so that the aerosol generating element is still visible. Preferably, "transparent" means a total light transmission percentage of 40% or more, more preferably 50% or more, even more preferably 60% or more, most preferably 70% or more, as measured using a Hunterlab Colorquest XE spectrophotometer or an equivalent spectrophotometer. The term "translucent" refers to a material that allows some level of light to pass through it, in particular with some scattering.

Preferably, the light transmittance of the portion of the wrapper surrounding the aerosol-generating element is at least 40 percent, preferably at least 50 percent, even more preferably at least 60 percent. The wrapper, which is at least partially substantially transparent or translucent, allows the user to see the contents of the aerosol-generating element of the article that the user is going to use.

Porous or breathable properties of the wrapping material or wrapper may allow the user to see the contents covered by the wrapper. For example, the wrapper may comprise (or be made from) a tea bag material or a tea bag-like material. The wrapper may comprise a biodegradable material. The wrapper may comprise polylactic acid (PLA). The wrapper may comprise a PLA mesh. The wrapper may comprise a material based on or formed from corn starch. The wrapper material may comprise wood or plant fibers.

The wrapper may comprise a polymer or plastic material that is breathable, such as nylon. The wrapper may comprise a paper material, such as filter paper. The inventors have found that such materials can be used to produce a wrapper that is sufficiently breathable, has a relatively high permeability (as indicated by the Coresta values above), and also allows the user to see the contents of the aerosol generating element to assess the type of aerosol generating element the user intends to use.

The wrapper may also be impregnated with a flavoring agent. In this way, some of the flavoring agent of the wrapper may be entrained in the air or released into the air flowing through the breathable wrapper into the aerosol-generating article or element. Such a flavoring agent may be a liquid or gel that may be applied to any other element or component of the aerosol-generating article, such as an aerosol-generating substrate as defined herein.

Preferably, the outer diameter of the aerosol generating element is substantially the same as the outer diameter of the rod. The aerosol generating element may be referred to as an aerosol generating segment or substrate.

The aerosol generating element may have a length of at least about 5 millimeters. Preferably, the aerosol generating element has a length of at least about 7 millimeters. More preferably, the aerosol generating element has a length of at least about 8 millimeters.

The aerosol generating element may have a length of up to about 25 millimeters. Preferably, the aerosol generating element has a length that is less than or equal to about 20 millimeters. More preferably, the aerosol generating element has a length that is less than or equal to about 13 millimeters.

The aerosol generating element may have a length of about 5 millimeters to about 25 millimeters, preferably about 7 millimeters to about 25 millimeters, more preferably about 8 millimeters to about 25 millimeters. The aerosol generating element may have a length of about 5 millimeters to about 20 millimeters, preferably about 7 millimeters to about 20 millimeters, more preferably about 8 millimeters to about 20 millimeters. The aerosol generating element may have a length of about 5 millimeters to about 13 millimeters, preferably about 7 millimeters to about 13 millimeters, more preferably about 8 millimeters to about 13 millimeters.

The aerosol generating element is a solid aerosol generating substrate containing tobacco plant material. The term "tobacco plant material" is used herein to mean material forming part of any plant belonging to the genus Nicotiana .

The aerosol generating element may contain homogenized tobacco material.

Homogenized tobacco material is an example of "homogenized plant material". As used herein, the term "homogenized plant material" encompasses any plant material formed by agglomerating plant particles. For example, sheets or webs of homogenized tobacco material for aerosol-generating substrates according to the present invention may be formed by agglomerating tobacco material particles obtained by grinding, crushing or milling one or more of tobacco leaf lamellas and tobacco leaf stems. Homogenized plant material, such as homogenized tobacco material, may be obtained by molding, extrusion, papermaking or any other suitable processes known in the art.

The homogenized tobacco material may be provided in any suitable form. For example, the homogenized tobacco material may be in the form of one or more sheets. In the context of this document, in relation to the present invention, the term "sheet" describes a layered element having a width and a length that are substantially greater than its thickness.

The homogenized tobacco material may be in the form of a plurality of pellets or granules.

The homogenized tobacco material may be in the form of a plurality of strands, strips or pieces. In the context of this document, the term "strand" describes an elongated element of material whose length significantly exceeds its width and thickness. The term "strand" should be considered as covering strips, pieces and any other homogenized tobacco material having a similar shape. The strands of homogenized tobacco material may be formed from a sheet of homogenized tobacco material, for example by cutting or shredding, or by other methods, for example by extrusion.

The threads may be formed in situ in the aerosol generating element as a result of dividing or splitting the sheet of homogenized tobacco material during the formation of the aerosol generating element, for example as a result of corrugating. The threads of homogenized tobacco material in the aerosol generating substrate may be separated from each other. Each thread of homogenized tobacco material in the aerosol generating element may be at least partially connected to adjacent thread or threads along the length of the threads. For example, adjacent threads may be connected by means of one or more fibers. This may occur, for example, if the threads were formed as a result of dividing the sheet of homogenized tobacco material during the production of the aerosol generating element, as described above.

Preferably, the aerosol generating element has the form of one or more sheets of homogenized tobacco material. The one or more sheets of homogenized tobacco material may be obtained by a molding process. The one or more sheets of homogenized tobacco material may be obtained by a paper making process. Each of the one or more sheets, as described herein, may individually have a thickness of from about 100 micrometers to 600 micrometers, preferably from 150 micrometers to 300 micrometers, and most preferably from 200 micrometers to 250 micrometers. The individual thickness refers to the thickness of an individual sheet, while the cumulative thickness refers to the total thickness of all sheets that make up the aerosol generating substrate. For example, if the aerosol generating element is formed from two separate sheets, then the combined thickness is the sum of the thicknesses of the two separate sheets or the measured thickness of the two sheets when the two sheets are stacked on top of each other in the aerosol generating substrate.

Each of the one or more sheets as described herein may individually have a grammage of from about 100 g/ ^m2 to about 300 g/ ^m2 .

Each of the one or more sheets as described herein may individually have a density of from about 0.3 g/ ^cm3 to about 1.3 g/ ^cm3 , and preferably from about 0.7 g/ ^cm3 to about 1.0 g/ ^cm3 .

One or more sheets of homogenized tobacco material are preferably in the form of one or more gathered sheets. In the context of this document, the term "gathered" means that the sheet of homogenized tobacco material is rolled, folded or otherwise compressed or narrowed substantially transversely to the cylindrical axis of the plug or rod.

One or more sheets of homogenized tobacco material may be assembled transversely to its longitudinal axis and surrounded by a wrapper to form a continuous rod or plug.

One or more sheets of homogenized tobacco material may advantageously be corrugated or similarly treated. As used herein, the term "corrugated" means a sheet having a plurality of substantially parallel folds or corrugations. One or more sheets of homogenized tobacco material may be embossed, blind embossed, perforated, or otherwise deformed to provide texture on one or both sides of the sheet.

Preferably, each sheet of homogenized tobacco material may be corrugated so that it has a plurality of folds or corrugations substantially parallel to the cylindrical axis of the plug. This treatment advantageously facilitates the collection of the corrugated sheet of homogenized tobacco material to form the plug. Preferably, one or more sheets of homogenized tobacco material may be collected. It will be understood that the corrugated sheets of homogenized tobacco material may have a plurality of substantially parallel folds or corrugations located at an acute or obtuse angle to the cylindrical axis of the plug. The sheet may be corrugated to such an extent that the integrity of the sheet is broken at the plurality of parallel folds or corrugations, which causes separation of the material and leads to the formation of pieces, threads or strips of homogenized tobacco material.

One or more sheets of homogenized tobacco material may be cut into threads as mentioned above. The aerosol-generating substrate may comprise a plurality of threads of homogenized tobacco material. The threads may be used to form a plug. Typically, the width of such threads is about 5 millimeters, or about 4 millimeters, or about 3 millimeters, or about 2 millimeters or less. The length of the threads may be greater than about 5 millimeters, from about 5 millimeters to about 15 millimeters, from about 8 millimeters to about 12 millimeters, or about 12 millimeters. Preferably, the threads have substantially the same length relative to each other. The length of the threads may be determined by a manufacturing process in which the rod is cut into shorter plugs, and the length of the threads corresponds to the length of the plug. The threads may be brittle, which may lead to breakage, especially during handling. In such cases, the length of some threads may be less than the length of the plug.

The plurality of threads preferably extend substantially longitudinally along the length of the aerosol generating element aligned with the longitudinal axis. Preferably, the plurality of threads are thus aligned substantially parallel to each other.

The homogenized tobacco material may contain up to about 95 percent by weight of plant particles on a dry weight basis. Preferably, the homogenized tobacco material contains up to about 90 percent by weight of plant particles, more preferably up to about 80 percent by weight of plant particles, more preferably up to about 70 percent by weight of plant particles, more preferably up to about 60 percent by weight of plant particles, more preferably up to about 50 percent by weight of plant particles on a dry weight basis.

For example, the homogenized tobacco material may contain from about 2.5 percent to about 95 percent by weight of plant particles, or from about 5 percent to about 90 percent by weight of plant particles, or from about 10 percent to about 80 percent by weight of plant particles, or from about 15 percent to about 70 percent by weight of plant particles, or from about 20 percent to about 60 percent by weight of plant particles, or from about 30 percent to about 50 percent by weight of plant particles on a dry weight basis.

The sheets of homogenized tobacco material for use in the present invention may have a tobacco content of at least about 40 percent by weight on a dry basis, more preferably at least about 50 percent by weight on a dry basis, more preferably at least about 70 percent by weight on a dry basis, and most preferably at least about 90 percent by weight on a dry basis.

In the context of the present invention, the term "tobacco particles" describes particles of any plant belonging to the genus Nicotiana. The term "tobacco particles" includes ground or powdered tobacco leaf blades, ground or powdered tobacco leaf stems, tobacco dust, tobacco fines and other tobacco by-products in the form of particles that are formed during the processing, handling and shipping of tobacco. The tobacco particles may be substantially all derived from tobacco leaf blades. In contrast, separated nicotine and nicotine salts are compounds derived from tobacco, but are not considered tobacco particles for the purposes of the present invention and are not included in the percentage of particulate plant material.

The tobacco particles may be derived from one or more varieties of tobacco plants. Any type of tobacco may be used in the blend. Examples of types of tobacco that may be used include, but are not limited to, sun-cured tobacco, flue-cured tobacco, Burley tobacco, Maryland tobacco, Oriental tobacco, Virginia tobacco, and other specialty tobaccos.

Flue-curing is a method of drying tobacco that is especially widely used with Virginia tobaccos. During the flue-curing process, heated air is circulated through tightly packed tobacco. During the first stage, the tobacco leaves turn yellow and wilt. During the second stage, the leaf blades are completely dry. During the third stage, the leaf stems are completely dry.

Burley tobacco plays an important role in many tobacco blends. Burley tobacco has a distinctive flavor and aroma, and also has the ability to absorb large amounts of sauce.

Oriental tobacco has small leaves and pronounced aromatic qualities. However, oriental tobacco has a milder flavor than, for example, Burley tobacco. Therefore, in general, oriental tobacco is used in relatively small proportions in tobacco blends.

Kasturi, Maduro and Yatim are subtypes of sun-cured tobacco that may be used. Preferably, Kasturi tobacco and flue-cured tobacco may be used in a mixture to produce tobacco particles. Accordingly, the tobacco particles in the particulate plant material may comprise a mixture of Kasturi tobacco and flue-cured tobacco.

The tobacco particles may have a nicotine content of at least about 2.5 percent by weight on a dry weight basis. More preferably, the tobacco particles may have a nicotine content of at least about 3 percent, even more preferably at least about 3.2 percent, even more preferably at least about 3.5 percent, most preferably at least about 4 percent by weight on a dry weight basis.

The aerosol generating element may comprise non-tobacco plant material. The homogenized tobacco material may comprise tobacco particles in combination with non-tobacco plant flavoring particles. Preferably, the non-tobacco plant flavoring particles are selected from one or more of: ginger particles, eucalyptus particles, anise particles, and star anise particles. Preferably, the homogenized tobacco material comprises at least about 2.5 percent by weight of non-tobacco plant flavoring particles based on dry weight, the remainder of the plant particles being tobacco particles. Preferably, the homogenized tobacco material comprises at least about 4 percent by weight of non-tobacco plant flavor particles, more preferably at least about 6 percent by weight of non-tobacco plant flavor particles, more preferably at least about 8 percent by weight of non-tobacco plant flavor particles, and more preferably at least about 10 percent by weight of non-tobacco plant flavor particles, based on dry weight. Preferably, the homogenized tobacco material comprises up to about 20 percent by weight of non-tobacco plant flavor particles, more preferably up to about 18 percent by weight of non-tobacco plant flavor particles, more preferably up to about 16 percent by weight of non-tobacco plant flavor particles.

The weight ratio of the non-tobacco plant flavouring particles to the tobacco particles in the particulate plant material forming the homogenised tobacco material may vary depending on the desired flavour characteristics and the composition of the aerosol obtained from the aerosol generating substrate during use. Preferably, the homogenised tobacco material has a weight ratio of at least 1:30 non-tobacco plant flavouring particles to tobacco particles, more preferably a weight ratio of at least 1:20 non-tobacco plant flavouring particles to tobacco particles, more preferably a weight ratio of at least 1:10 non-tobacco plant flavouring particles to tobacco particles, and most preferably a weight ratio of at least 1:5 non-tobacco plant flavouring particles to tobacco particles, based on dry weight.

The homogenized tobacco material preferably contains no more than 95 percent by weight of particulate plant material on a dry weight basis. Therefore, the particulate plant material is typically combined with one or more other components to form the homogenized tobacco material.

The homogenized tobacco material may further comprise a binder for changing the mechanical properties of the particulate plant material, wherein the binder is incorporated into the homogenized tobacco material during manufacture as described herein. Suitable exogenous binders are known to those skilled in the art and include, but are not limited to: gums such as, for example, guar gum, xanthan gum, acacia and locust bean gum; cellulose binders such as, for example, hydroxypropyl cellulose, carboxymethyl cellulose, hydroxyethyl cellulose, methyl cellulose and ethyl cellulose; polysaccharides such as, for example, starches, organic acids such as alginic acid, salts of conjugate bases with organic acids such as sodium alginate, agar and pectins; and combinations thereof. Preferably, the binder comprises guar gum.

The binder may be present in an amount of from about 1 percent to about 10 percent by weight based on the dry weight of the homogenized tobacco material, preferably in an amount of from about 2 percent to about 5 percent by weight based on the dry weight of the homogenized tobacco material.

The homogenized tobacco material may further comprise one or more lipids that promote the diffusion of volatile components (e.g., aerosol forming agents, gingerols, and nicotine), wherein the lipid is included in the homogenized tobacco material during manufacture as described herein. Lipids suitable for inclusion in the homogenized tobacco material include, but are not limited to: medium chain triglycerides, cocoa butter, palm oil, palm kernel oil, mango butter, shea butter, soybean oil, cottonseed oil, coconut oil, hydrogenated coconut oil, candelilla wax, carnauba wax, shellac, sunflower wax, sunflower oil, rice bran, and Revel A; and combinations thereof.

The homogenized tobacco material may additionally contain a pH modifier.

The homogenized tobacco material may further comprise fibers for altering the mechanical properties of the homogenized tobacco material, wherein the fibers are incorporated into the homogenized tobacco material during manufacture as described herein. Suitable exogenous fibers for inclusion in the homogenized tobacco material are known in the art and include fibers formed from non-tobacco material and non-ginger material, including, but not limited to: cellulose fibers; softwood fibers; hardwood fibers; jute fibers and combinations thereof. Exogenous fibers derived from tobacco and/or ginger may also be added. Any fibers added to the homogenized tobacco material are not considered to form part of the "particulate plant material" as defined above. Prior to incorporation into the homogenized tobacco material, the fibers may be processed by suitable processes known in the art, including, but not limited to: mechanical pulping; cleaning; chemical pulping; bleaching; kraft cooking; and their combinations. The fiber is usually longer than its width.

Suitable fibers typically have lengths greater than 400 micrometers and less than or equal to 4 millimeters, preferably in the range of 0.7 millimeters to 4 millimeters. Preferably, the fibers are present in an amount of from about 2 percent to about 15 percent by weight, most preferably at a level of about 4 percent by weight, based on the dry weight of the substrate.

In the context of the present invention, the aerosol generating element further comprises one or more aerosol forming agents. After evaporation, the aerosol forming agent may carry other vaporized compounds released from the aerosol generating element upon heating, such as nicotine and flavoring agents, in the aerosol. Suitable aerosol forming agents for inclusion in the aerosol generating element are known in the art and include, but are not limited to: polyhydric alcohols such as triethylene glycol, propylene glycol, 1,3-butanediol and glycerol; esters of polyhydric alcohols such as glycerol mono-, di- or triacetate; and aliphatic esters of mono-, di- or polycarboxylic acids such as dimethyl dodecanedioate and dimethyl tetradecanedioate.

The aerosol generating element may comprise two or more of homogenized tobacco material, tobacco molded sheet, and reconstituted tobacco.

As an example, the aerosol generating element may comprise a sheet of homogenized tobacco material that is obtained from a mixture of high-quality leaf tobacco material, and wherein the aerosol forming substance is directly combined with the leaf tobacco material before forming a sheet from the resulting mixture. One such homogenized tobacco material may be combined with a tobacco molded sheet or reconstituted tobacco, or both. The tobacco molded sheet or reconstituted tobacco, or both, may, for example, be a standard molded sheet or a standard reconstituted tobacco formed from tobacco particles, including, but not limited to, reconstituted tobacco particles, wherein the standard molded sheet or the standard reconstituted tobacco is impregnated with the aerosol forming substance after being formed into a sheet.

The inventors of the present invention have found that when heated under the same conditions and for the same period of time, these tobacco materials can have different aerosol delivery profiles. In particular, the standard tobacco molded sheet can tend to release aerosol species earlier and at lower temperatures compared to the standard reconstituted tobacco. In turn, the standard reconstituted tobacco can tend to release aerosol species earlier and at lower temperatures compared to the homogenized tobacco material, as described above. Thus, by adjusting the relative proportions of these different tobacco materials in the aerosol generating element, it is possible to advantageously fine-tune the timing and intensity of aerosol delivery from the aerosol generating element during use.

The aerosol generating element may have an aerosol forming agent content of from about 5 percent to about 30 percent by weight on a dry weight basis.

Preferably, the aerosol generating element has an aerosol forming substance content of at least about 10 percent by weight on a dry weight basis, more preferably at least about 15 percent by weight on a dry weight basis.

The aerosol generating element preferably has an aerosol forming substance content that is less than or equal to about 25 percent by weight on a dry weight basis, more preferably less than or equal to about 20 percent by weight on a dry weight basis.

The aerosol generating element may have an aerosol forming substance content of 5 percent to 25 percent by weight based on dry weight, preferably 10 percent to 25 percent by weight based on dry weight, more preferably 15 percent to 25 percent by weight based on dry weight. The aerosol generating element may have an aerosol forming substance content of 5 percent to 20 percent by weight based on dry weight, preferably 10 percent to 20 percent by weight based on dry weight, more preferably 15 percent to 20 percent by weight based on dry weight.

The aerosol generating element may have an aerosol forming agent content of from about 30 percent by weight to about 45 percent by weight. This relatively high level of aerosol forming agent is particularly suitable for an aerosol generating element that is designed to be heated at a temperature of less than 275 degrees Celsius. The aerosol generating element preferably comprises a homogenized tobacco material containing from about 2 percent by weight to about 10 percent by weight of a cellulose ether on a dry weight basis and from about 5 percent by weight to about 50 percent by weight of additional cellulose on a dry weight basis. It has been found that the use of a combination of cellulose ether and additional cellulose provides particularly effective aerosol delivery when used in an aerosol generating substrate having an aerosol forming agent content of from 30 percent by weight to 45 percent by weight.

Suitable cellulose ethers include, but are not limited to, methylcellulose, hydroxypropylmethylcellulose, ethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, ethylhydroxyethylcellulose, and carboxymethylcellulose (CMC). The cellulose ether may be carboxymethylcellulose.

As used herein, the term "additional cellulose" encompasses any cellulosic material included in the homogenized tobacco material that does not originate from non-tobacco plant particles or tobacco particles provided in the homogenized tobacco material. Therefore, the additional cellulose is included in the homogenized tobacco material in addition to the non-tobacco plant material or tobacco material as a separate source of cellulose that is distinct from any cellulose inherently present in the non-tobacco plant particles or tobacco particles. The additional cellulose typically originates from a plant other than the non-tobacco plant particles or tobacco particles. Preferably, the additional cellulose is in the form of an inert cellulose material that is inert to the senses and therefore does not significantly affect the organoleptic characteristics of the aerosol generated from the aerosol-generating substrate. For example, the additional cellulose is preferably a tasteless and odorless material.

Supplementary cellulose may contain cellulose powder, cellulose fibers, or a combination of both.

An aerosol forming agent may act as a humectant in the aerosol generating element or substrate.

The aerosol generating element may comprise a plug made of a porous substrate.

The term "porous substrate" is used herein to describe a material that provides a plurality of pores or openings that allow air to pass through the material. The porous substrate may be any suitable porous material capable of holding or retaining an aerosol-generating medium or flavoring agent, particularly if they are in the form of a liquid or gel, as discussed below.

The advantage of a porous substrate filled with an aerosol-generating medium or a flavoring agent is that the aerosol-generating medium or flavoring agent is retained within the porous medium, and this can facilitate the manufacture, storage or transportation of the gel composition. This is particularly effective when the aerosol-generating medium or flavoring agent is in the form of a gel, since the use of a porous substrate can help preserve the gel and keep the gel in the desired position in the core, especially during production and transportation, as well as during use.

The porous substrate may comprise natural materials, synthetic or semi-synthetic materials, or a combination thereof. The porous substrate may comprise a sheet material, a foam material, or fibers, such as loose fibers, or a combination thereof. The porous substrate may comprise a woven, non-woven, or extruded material, or a combination thereof. Preferably, the porous substrate comprises cotton, paper, viscose, PLA, or cellulose acetate, or a combination thereof. The porous substrate may comprise a collected sheet material, such as one made of cotton or cellulose acetate.

The aerosol generating medium may comprise a liquid or gel impregnated into a porous substrate.

The aerosol generating medium may comprise a gel containing an alkaloid compound; an aerosol forming substance; and at least one gelling agent.

The term "alkaloid compound" refers to any of a class of naturally occurring organic compounds that contain one or more basic nitrogen atoms. Typically, an alkaloid contains at least one nitrogen atom in an amine-type structure. This or another nitrogen atom in the alkaloid compound molecule may be active as a base in acid-base reactions. Most alkaloid compounds have one or more nitrogen atoms as part of a cyclic system, such as, for example, a heterocyclic ring. In nature, alkaloid compounds are found primarily in plants and are especially common in certain families of flowering plants. However, some alkaloid compounds are found in animal species and in fungi. As used herein, the term "alkaloid compound" refers to both naturally occurring alkaloid compounds and synthetically produced alkaloid compounds.

The gel may preferably contain an alkaloid compound selected from the group consisting of nicotine, anatabine and combinations thereof.

Preferably the gel contains nicotine.

The term "nicotine" refers to nicotine and nicotine derivatives such as pure nicotine, nicotine salts, etc.

The gel preferably contains from about 0.5 percent by weight to about 10 percent by weight of the alkaloid compound. The gel may contain from about 0.5 percent by weight to about 5 percent by weight of the alkaloid compound. Preferably, the gel contains from about 1 percent by weight to about 3 percent by weight of the alkaloid compound. The gel may preferably contain from about 1.5 percent by weight to about 2.5 percent by weight of the alkaloid compound. The gel may preferably contain about 2 percent by weight of the alkaloid compound.

The alkaloid compound component of the gel may be the most volatile component of the gel. The gel may contain water, and the water may be the most volatile component of the gel, and the alkaloid compound component of the gel may be the second most volatile component of the gel.

Preferably, the nicotine is contained in a gel. Nicotine may be added to the gel composition in the form of a free base or in the form of a salt.

The gel contains from about 0.5 percent by weight to about 10 percent by weight nicotine, or from about 0.5 percent by weight to about 5 percent by weight nicotine. Preferably, the gel contains from about 1 percent by weight to about 3 percent by weight nicotine, or from about 1.5 percent by weight to about 2.5 percent by weight nicotine, or about 2 percent by weight nicotine.

As briefly described above, the gel preferably further comprises an aerosol former. Ideally, the aerosol former is substantially resistant to thermal decomposition at the operating temperature of the associated aerosol generating device. Suitable aerosol formers include, but are not limited to: polyhydric alcohols such as triethylene glycol, 1,3-butanediol and glycerol; esters of polyhydric alcohols such as glycerol mono-, di- or triacetate; and aliphatic esters of mono-, di- or polycarboxylic acids such as dimethyl dodecanedioate and dimethyl tetradecanedioate. The polyhydric alcohols or mixtures thereof may be one or more of the following: triethylene glycol, 1,3-butanediol and glycerol (glycerol or propane-1,2,3-triol) or polyethylene glycol. The aerosol former is preferably glycerol.

The gel may contain a majority of the aerosol forming agent. The gel may contain a mixture of water and the aerosol forming agent, wherein the aerosol forming agent forms a majority (by weight) of the gel. The aerosol forming agent may form at least about 50 percent by weight of the gel. The aerosol forming agent may form at least about 60 percent by weight, or at least about 65 percent by weight, or at least about 70 percent by weight of the gel. The aerosol forming agent may form from about 70 percent by weight to about 80 percent by weight of the gel. The aerosol forming agent may form from about 70 percent by weight to about 75 percent by weight of the gel.

The gel may contain a majority of glycerol. The gel may contain a mixture of water and glycerol, wherein glycerol forms a majority (by weight) of the gel. Glycerol may form at least about 50 percent by weight of the gel. Glycerol may form at least about 60 percent by weight, or at least about 65 percent by weight, or at least about 70 percent by weight of the gel. Glycerol may form from about 70 percent by weight to about 80 percent by weight of the gel. Glycerol may form from about 70 percent by weight to about 75 percent by weight of the gel.

The gel further preferably comprises at least one gelling agent. Preferably, the gel composition comprises a total amount of gelling agents in the range of about 0.4 percent by weight to about 10 percent by weight. More preferably, the gel comprises gelling agents in the range of about 0.5 percent by weight to about 8 percent by weight. More preferably, the gel comprises gelling agents in the range of about 1 percent by weight to about 6 percent by weight. More preferably, the gel comprises gelling agents in the range of about 2 percent by weight to about 4 percent by weight. More preferably, the gel comprises gelling agents in the range of about 2 percent by weight to about 3 percent by weight.

The term "gelling agent" refers to a compound that uniformly, when added to a 50 percent by weight water/50 percent by weight glycerol mixture, in an amount of about 0.3 percent by weight, forms a solid medium or support matrix resulting in the formation of a gel. Gelling agents include, but are not limited to, gelling agents that provide crosslinking through hydrogen bonding and gelling agents that provide crosslinking through ionic bonding.

The gelling agent may include one or more biopolymers. The biopolymers may be formed from polysaccharides.

Biopolymers include, for example, gellan gums (natural, low acyl gellan gum, high acyl gellan gums, with low acyl gellan gum being preferred), xanthan gum, alginates (alginic acid), agar, guar gum, etc. The composition may preferably include xanthan gum. The composition may include two biopolymers. The composition may include three biopolymers. The composition may include two biopolymers in substantially equal weights. The composition may include three biopolymers in substantially equal weights.

Preferably, the gel comprises at least about 0.2 percent by weight of a gelling agent that provides crosslinking via hydrogen bonds. The gel preferably comprises at least about 0.2 percent by weight of a gelling agent that provides crosslinking via ionic bonds. Most preferably, the gel comprises at least about 0.2 percent by weight of a gelling agent that provides crosslinking via hydrogen bonds and at least about 0.2 percent by weight of a gelling agent that provides crosslinking via ionic bonds. The gel may contain from about 0.5 percent by weight to about 3 percent by weight of a gelling agent that provides crosslinking through hydrogen bonds and from about 0.5 percent by weight to about 3 percent by weight of a gelling agent that provides crosslinking through ionic bonds, or from about 1 percent by weight to about 2 percent by weight of a gelling agent that provides crosslinking through hydrogen bonds and from about 1 percent by weight to about 2 percent by weight of a gelling agent that provides crosslinking through ionic bonds. The gelling agent that provides crosslinking through hydrogen bonds and the gelling agent that provides crosslinking through ionic bonds may be present in the gel in substantially equal amounts by weight.

The term "hydrogen bonding gelling agent" refers to a gelling agent that forms non-covalent cross-linking bonds or physical cross-linking bonds through hydrogen bonding. Hydrogen bonding is a type of electrostatic dipole-dipole attraction between molecules rather than a covalent bond to a hydrogen atom. It results from the attractive force between a hydrogen atom covalently bonded to a highly electronegative atom, such as an N, O, or F atom, and another highly electronegative atom.

The gelling agent providing crosslinking by hydrogen bonds may comprise one or more of galactomannan, gelatin, agarose or konjac gum, or agar. The gelling agent providing crosslinking by hydrogen bonds may preferably comprise agar.

The gel preferably contains a gelling agent providing crosslinking by hydrogen bonds in a range of from about 0.3 percent by weight to about 5 percent by weight. Preferably, the gel contains a gelling agent providing crosslinking by hydrogen bonds in a range of from about 0.5 percent by weight to about 3 percent by weight. Preferably, the gel contains a gelling agent providing crosslinking by hydrogen bonds in a range of from about 1 percent by weight to about 2 percent by weight.

The gel may contain galactomannan in a range of from about 0.2 percent by weight to about 5 percent by weight. Preferably, galactomannan may be present in a range of from about 0.5 percent by weight to about 3 percent by weight. Preferably, galactomannan may be present in a range of from about 0.5 percent by weight to about 2 percent by weight. Preferably, galactomannan may be present in a range of from about 1 percent by weight to about 2 percent by weight.

The gel may contain gelatin in a range of from about 0.2 percent by weight to about 5 percent by weight. Preferably, the gelatin may be present in a range of from about 0.5 percent by weight to about 3 percent by weight. Preferably, the gelatin may be present in a range of from about 0.5 percent by weight to about 2 percent by weight. Preferably, the gelatin may be present in a range of from about 1 percent by weight to about 2 percent by weight.

The gel may contain agarose in a range of from about 0.2 percent by weight to about 5 percent by weight. Preferably, agarose may be present in a range of from about 0.5 percent by weight to about 3 percent by weight. Preferably, agarose may be present in a range of from about 0.5 percent by weight to about 2 percent by weight. Preferably, agarose may be present in a range of from about 1 percent by weight to about 2 percent by weight.

The gel may contain konjac gum in a range of from about 0.2 percent by weight to about 5 percent by weight. Preferably, konjac gum may be present in a range of from about 0.5 percent by weight to about 3 percent by weight. Preferably, konjac gum may be present in a range of from about 0.5 percent by weight to about 2 percent by weight. Preferably, konjac gum may be present in a range of from about 1 percent by weight to about 2 percent by weight.

The gel may contain agar in a range of from about 0.2 percent by weight to about 5 percent by weight. Preferably, agar may be present in a range of from about 0.5 percent by weight to about 3 percent by weight. Preferably, agar may be present in a range of from about 0.5 percent by weight to about 2 percent by weight. Preferably, agar may be present in a range of from about 1 percent by weight to about 2 percent by weight.

The term "ionic crosslinking gelling agent" refers to a gelling agent that forms non-covalent crosslinking bonds or physical crosslinking bonds through the formation of ionic bonds. Ionic crosslinking involves the linking of polymer chains through non-covalent interactions. A crosslinked network is formed when polyvalent molecules of opposite charges are electrostatically attracted to each other, resulting in the formation of a crosslinked polymer network.

The gelling agent providing crosslinking by ionic bonds may comprise low acyl gellan, pectin, kappa carrageenan, iota carrageenan or alginate. The gelling agent providing crosslinking by ionic bonds may preferably comprise low acyl gellan.

The gel may contain a gelling agent providing crosslinking through ionic bonds in a range from about 0.3 percent by weight to about 5 percent by weight. Preferably, the gel contains a gelling agent providing crosslinking through ionic bonds in a range from about 0.5 percent by weight to about 3 percent by weight. Preferably, the gel contains a gelling agent providing crosslinking through ionic bonds in a range from about 1 percent by weight to about 2 percent by weight.

The gel may contain low acyl gellan in a range of from about 0.2 percent by weight to about 5 percent by weight. Preferably, the low acyl gellan may be present in a range of from about 0.5 percent by weight to about 3 percent by weight. Preferably, the low acyl gellan may be present in a range of from about 0.5 percent by weight to about 2 percent by weight. Preferably, the low acyl gellan may be present in a range of from about 1 percent by weight to about 2 percent by weight.

The gel may contain pectin in a range of from about 0.2 percent by weight to about 5 percent by weight. Preferably, the pectin may be present in a range of from about 0.5 percent by weight to about 3 percent by weight. Preferably, the pectin may be present in a range of from about 0.5 percent by weight to about 2 percent by weight. Preferably, the pectin may be present in a range of from about 1 percent by weight to about 2 percent by weight.

The gel may contain kappa carrageenan in a range of from about 0.2 percent by weight to about 5 percent by weight. Preferably, kappa carrageenan may be present in a range of from about 0.5 percent by weight to about 3 percent by weight. Preferably, kappa carrageenan may be present in a range of from about 0.5 percent by weight to about 2 percent by weight. Preferably, kappa carrageenan may be present in a range of from about 1 percent by weight to about 2 percent by weight.

The gel may contain iota-carrageenan in a range of from about 0.2 percent by weight to about 5 percent by weight. Preferably, iota-carrageenan may be present in a range of from about 0.5 percent by weight to about 3 percent by weight. Preferably, iota-carrageenan may be present in a range of from about 0.5 percent by weight to about 2 percent by weight. Preferably, iota-carrageenan may be present in a range of from about 1 percent by weight to about 2 percent by weight.

The gel may contain alginate in a range of from about 0.2 percent by weight to about 5 percent by weight. Preferably, the alginate may be present in a range of from about 0.5 percent by weight to about 3 percent by weight. Preferably, the alginate may be present in a range of from about 0.5 percent by weight to about 2 percent by weight. Preferably, the alginate may be present in a range of from about 1 percent by weight to about 2 percent by weight.

The gel may contain a gelling agent providing crosslinking by means of hydrogen bonds and a gelling agent providing crosslinking by means of ionic bonds in a ratio of about 3:1 to about 1:3. Preferably, the gel may contain a gelling agent providing crosslinking by means of hydrogen bonds and a gelling agent providing crosslinking by means of ionic bonds in a ratio of about 2:1 to about 1:2. Preferably, the gel may contain a gelling agent providing crosslinking by means of hydrogen bonds and a gelling agent providing crosslinking by means of ionic bonds in a ratio of about 1:1.

The gel may further comprise a viscosity increasing agent. The viscosity increasing agent in combination with a gelling agent providing crosslinking by hydrogen bonds and a gelling agent providing crosslinking by ionic bonds appears to unexpectedly maintain a solid environment and preserve the gel composition, even if the gel composition contains a high level of glycerol.

The term "viscosity increasing agent" refers to a compound which, when uniformly added to a 50 percent by weight water/50 percent by weight glycerol mixture at 25 °C in an amount of 0.3 percent by weight, increases the viscosity without causing gel formation, while the mixture remains or remains liquid. Preferably, the viscosity increasing agent refers to a compound which, when uniformly added to a 50 percent by weight water/50 percent by weight glycerol mixture at 25 °C in an amount of 0.3 percent by weight, increases the viscosity to at least 50 cP, preferably at least 200 cP, preferably at least 500 cP, preferably at least 1000 cP at a shear rate of 0.1 s ^-1 , without causing gel formation, while the mixture remains or remains liquid. Preferably, the viscosity increasing agent refers to a compound which, when uniformly added to a 50 percent by weight water/50 percent by weight glycerol mixture at 25 °C in an amount of 0.3 percent by weight, increases the viscosity by at least 2 times, or at least 5 times, or at least 10 times, or at least 100 times than before addition, at a shear rate of 0.1 s ^-1 , without causing gel formation, while the mixture remains or remains liquid.

The viscosity values given in this document can be measured using a Brookfield RVT viscometer rotating an RV#2 disc type shaft at 25°C at 6 revolutions per minute (rpm).

The gel preferably contains a viscosity increasing agent in the range of about 0.2 percent by weight to about 5 percent by weight. Preferably, the gel contains a viscosity increasing agent in the range of about 0.5 percent by weight to about 3 percent by weight. Preferably, the gel contains a viscosity increasing agent in the range of about 0.5 percent by weight to about 2 percent by weight. Preferably, the gel contains a viscosity increasing agent in the range of about 1 percent by weight to about 2 percent by weight.

The viscosity increasing agent may comprise one or more of xanthan gum, carboxymethyl cellulose, microcrystalline cellulose, methyl cellulose, acacia, guar gum, lambda carrageenan or starch. The viscosity increasing agent may preferably comprise xanthan gum.

The gel may contain xanthan gum in a range of from about 0.2 percent by weight to about 5 percent by weight. Preferably, xanthan gum may be present in a range of from about 0.5 percent by weight to about 3 percent by weight. Preferably, xanthan gum may be present in a range of from about 0.5 percent by weight to about 2 percent by weight. Preferably, xanthan gum may be present in a range of from about 1 percent by weight to about 2 percent by weight.

The gel may contain carboxymethylcellulose in a range of from about 0.2 percent by weight to about 5 percent by weight. Preferably, carboxymethylcellulose may be present in a range of from about 0.5 percent by weight to about 3 percent by weight. Preferably, carboxymethylcellulose may be present in a range of from about 0.5 percent by weight to about 2 percent by weight. Preferably, carboxymethylcellulose may be present in a range of from about 1 percent by weight to about 2 percent by weight.

The gel may contain microcrystalline cellulose in a range of from about 0.2 percent by weight to about 5 percent by weight. Preferably, the microcrystalline cellulose may be present in a range of from about 0.5 percent by weight to about 3 percent by weight. Preferably, the microcrystalline cellulose may be present in a range of from about 0.5 percent by weight to about 2 percent by weight. Preferably, the microcrystalline cellulose may be present in a range of from about 1 percent by weight to about 2 percent by weight.

The gel may contain methylcellulose in a range of from about 0.2 percent by weight to about 5 percent by weight. Preferably, methylcellulose may be present in a range of from about 0.5 percent by weight to about 3 percent by weight. Preferably, methylcellulose may be present in a range of from about 0.5 percent by weight to about 2 percent by weight. Preferably, methylcellulose may be present in a range of from about 1 percent by weight to about 2 percent by weight.

The gel may contain acacia in a range of from about 0.2 percent by weight to about 5 percent by weight. Preferably, the acacia may be present in a range of from about 0.5 percent by weight to about 3 percent by weight. Preferably, the acacia may be present in a range of from about 0.5 percent by weight to about 2 percent by weight. Preferably, the acacia may be present in a range of from about 1 percent by weight to about 2 percent by weight.

The gel may contain guar gum in a range of from about 0.2 percent by weight to about 5 percent by weight. Preferably, guar gum may be present in a range of from about 0.5 percent by weight to about 3 percent by weight. Preferably, guar gum may be present in a range of from about 0.5 percent by weight to about 2 percent by weight. Preferably, guar gum may be present in a range of from about 1 percent by weight to about 2 percent by weight.

The gel may contain lambda carrageenan in a range of from about 0.2 percent by weight to about 5 percent by weight. Preferably, lambda carrageenan may be present in a range of from about 0.5 percent by weight to about 3 percent by weight. Preferably, lambda carrageenan may be present in a range of from about 0.5 percent by weight to about 2 percent by weight. Preferably, lambda carrageenan may be present in a range of from about 1 percent by weight to about 2 percent by weight.

The gel may contain starch in a range of from about 0.2 percent by weight to about 5 percent by weight. Preferably, the starch may be present in a range of from about 0.5 percent by weight to about 3 percent by weight. Preferably, the starch may be present in a range of from about 0.5 percent by weight to about 2 percent by weight. Preferably, the starch may be in a range of from about 1 percent by weight to about 2 percent by weight.

The gel may further comprise a divalent cation. Preferably, the divalent cation comprises calcium ions, such as calcium lactate in solution. Divalent cations (such as calcium ions) may promote gelling of compositions that contain gelling agents, such as, for example, a gelling agent that provides crosslinking through ionic bonds. The ionic effect may promote gelling. The divalent cation may be present in the gel composition in a range of from about 0.1 to about 1 percent by weight, or from about 0.5 percent by weight to about 1 percent by weight.

The gel may further comprise an acid. The acid may comprise a carboxylic acid. The carboxylic acid may comprise a ketone group. Preferably, the carboxylic acid may comprise a ketone group having less than about 10 carbon atoms, or less than about 6 carbon atoms, or less than about 4 carbon atoms, such as levulinic acid or lactic acid. Preferably, this carboxylic acid has three carbon atoms (e.g., lactic acid). Lactic acid unexpectedly improves the stability of the gel even compared to similar carboxylic acids. The carboxylic acid may promote gel formation. The carboxylic acid may reduce the change in the concentration of the alkaloid compound within the gel during storage. The carboxylic acid may reduce the change in the concentration of nicotine within the gel during storage.

The gel may contain a carboxylic acid in a range from about 0.1 percent by weight to about 5 percent by weight. Preferably, the carboxylic acid may be present in a range from about 0.5 percent by weight to about 3 percent by weight. Preferably, the carboxylic acid may be present in a range from about 0.5 percent by weight to about 2 percent by weight. Preferably, the carboxylic acid may be present in a range from about 1 percent by weight to about 2 percent by weight.

The gel may contain lactic acid in a range of from about 0.1 percent by weight to about 5 percent by weight. Preferably, lactic acid may be present in a range of from about 0.5 percent by weight to about 3 percent by weight. Preferably, lactic acid may be present in a range of from about 0.5 percent by weight to about 2 percent by weight. Preferably, lactic acid may be present in a range of from about 1 percent by weight to about 2 percent by weight.

The gel may contain levulinic acid in a range of from about 0.1 percent by weight to about 5 percent by weight. Preferably, levulinic acid may be present in a range of from about 0.5 percent by weight to about 3 percent by weight. Preferably, levulinic acid may be present in a range of from about 0.5 percent by weight to about 2 percent by weight. Preferably, levulinic acid may be present in a range of from about 1 percent by weight to about 2 percent by weight.

The gel preferably contains some water. The gel is more stable when the gel contains some water. Preferably, the gel contains at least about 1 percent by weight, or at least about 2 percent by weight, or at least about 5 percent by weight of water. Preferably, the gel contains at least about 10 percent by weight, or at least about 15 percent by weight of water.

Preferably, the gel contains from about 8 percent by weight to about 32 percent by weight of water. Preferably, the gel contains from about 15 percent by weight to about 25 percent by weight of water. Preferably, the gel contains from about 18 percent by weight to about 22 percent by weight of water. Preferably, the gel contains about 20 percent by weight of water.

The aerosol-generating article according to the present invention comprises an aerosol-generating rod as described above and may further comprise a downstream section at a location downstream of the aerosol-generating rod, which, as described above, comprises a first segment in the form of a plug, an aerosol-generating element, and a second segment in the form of a plug or consists of them. The aerosol-generating article according to the present invention may comprise an upstream section at a location upstream of the aerosol-generating rod.

A downstream section may comprise one or more downstream elements.

The downstream section may comprise a support member that is aligned with and downstream of the aerosol generating rod. In particular, the support member may be positioned immediately downstream of the aerosol generating rod and may be adjacent to the aerosol generating rod.

The support member may be formed from any suitable material or combination of materials. For example, the support member may be formed from one or more materials selected from the group consisting of: cellulose acetate; cardboard; corrugated paper, such as corrugated heat-resistant paper or corrugated parchment paper; and polymeric materials, such as low-density polyethylene (LDPE). The support member may be formed from cellulose acetate. Other suitable materials include polyhydroxyalkanoate (PHA) fibers.

The support member may comprise a hollow tubular segment. The support member may comprise a hollow tube made of cellulose acetate.

The support element may be arranged substantially in alignment with the aerosol generating rod. This means that the length dimension of the support element is adapted approximately parallel to the longitudinal direction of the rod and the article, for example within plus or minus 10 degrees from parallel to the longitudinal direction of the rod. The support element may extend along the longitudinal axis of the rod.

The support member preferably has an outer diameter approximately equal to the outer diameter of the aerosol generating rod.

The peripheral wall of the support element may have a thickness of at least 1 millimeter, preferably at least about 1.5 millimeters, more preferably at least about 2 millimeters.

The support element may have a length of about 5 millimeters to about 15 millimeters. Preferably, the support element has a length of at least about 6 millimeters, more preferably at least about 7 millimeters. The support element may have a length of less than about 12 millimeters, more preferably less than about 10 millimeters.

The support element may have a length of about 5 millimeters to about 15 millimeters, preferably about 6 millimeters to about 15 millimeters, more preferably about 7 millimeters to about 15 millimeters. The support element may have a length of about 5 millimeters to about 12 millimeters, preferably about 6 millimeters to about 12 millimeters, more preferably about 7 millimeters to about 12 millimeters. The support element may have a length of about 5 millimeters to about 10 millimeters, preferably about 6 millimeters to about 10 millimeters, more preferably about 7 millimeters to about 10 millimeters.

The support element may be approximately 8 millimetres long.

Preferably, the hollow tubular segment of the support member is adapted to generate an RTD of from about 0 millimeters of water column (about 0 Pa) to about 20 millimeters of water column (about 100 Pa), more preferably from about 0 millimeters of water column (about 0 Pa) to about 10 millimeters of water column (about 100 Pa). Therefore, the support member preferably does not contribute to the overall RTD of the aerosol-generating article.

The downstream section of the aerosol generating article may comprise a mouthpiece element located downstream of the aerosol generating rod and in longitudinal alignment with the aerosol generating rod.

The mouthpiece element is preferably located at the downstream end, or mouthpiece end, of the aerosol generating article and extends the entire distance to the mouthpiece end of the aerosol generating article.

Preferably, the mouthpiece element comprises at least one filter segment of the mouthpiece made of a fibrous filter material for filtering the aerosol generated from the aerosol-generating substrate. Suitable fibrous filter materials will be known to a person skilled in the art. Particularly preferably, at least one filter segment of the mouthpiece comprises a filter segment of cellulose acetate formed from a cellulose acetate tow.

The mouthpiece element may consist of one filtering mouthpiece segment. The mouthpiece element may comprise two or more filtering mouthpiece segments aligned axially with each other in end-to-end contact.

The downstream section may comprise a mouth end cavity at the downstream end, downstream of the mouth end member, as described above. The mouth end cavity may be formed by a hollow tubular element provided at the downstream end of the mouth end member. The mouth end cavity may be formed by an outer wrapper of the mouth end member, wherein the outer wrapper extends in a direction downstream of the mouth end member.

The mouthpiece element may optionally contain a flavoring agent, which may be provided in any suitable form. For example, the mouthpiece element may contain one or more capsules, beads or granules of a flavoring agent, or one or more threads or fibers filled with a flavoring agent.

The downstream section of the aerosol generating article may further comprise both a support element positioned immediately downstream of the aerosol generating rod and a mouthpiece element positioned downstream of the support element.

Preferably, the mouthpiece element has a low particle filtration efficiency.

Preferably, the mouthpiece is formed from a segment of fibrous filter material.

Preferably, the mouthpiece element is surrounded by a wick. Preferably, the mouthpiece element is not ventilated, so that air does not enter the aerosol-generating article along the mouthpiece element.

The mouthpiece element is preferably connected to one or more adjacent upstream components of the aerosol generating article by means of a rim wrap.

Preferably, the mouthpiece element has an RTD of less than about 25 millimeters of water column. More preferably, the mouthpiece element has an RTD of less than about 20 millimeters of water column. Even more preferably, the mouthpiece element has an RTD of less than about 15 millimeters of water column.

RTD values of from about 10 millimeters of water column to about 15 millimeters of water column are particularly preferred since a mouthpiece element having one such RTD value is expected to make a minimal contribution to the overall RTD of the aerosol-generating article and to have substantially no filtering effect on the aerosol delivered to the consumer.

The mouthpiece element preferably has an outer diameter that is approximately equal to the outer diameter of the aerosol generating article.

The mouthpiece element preferably has a length of at least about 5 millimeters, more preferably at least about 8 millimeters, more preferably at least about 10 millimeters. The mouthpiece element preferably has a length of less than about 25 millimeters, more preferably less than about 20 millimeters, more preferably less than about 15 millimeters.

The mouthpiece element preferably has a length of about 5 millimeters to about 25 millimeters, more preferably about 8 millimeters to about 25 millimeters, even more preferably about 10 millimeters to about 25 millimeters. The mouthpiece element preferably has a length of about 5 millimeters to about 10 millimeters, more preferably about 8 millimeters to about 20 millimeters, even more preferably about 10 millimeters to about 20 millimeters. The mouthpiece element preferably has a length of about 5 millimeters to about 15 millimeters, more preferably about 8 millimeters to about 15 millimeters, even more preferably about 10 millimeters to about 15 millimeters.

For example, the mouthpiece element may have a length of about 5 millimeters to about 25 millimeters, or about 8 millimeters to about 20 millimeters, or about 10 millimeters to about 15 millimeters. The mouthpiece element may have a length of about 12 millimeters.

The downstream section may further comprise an aerosol cooling element arranged downstream of the support element, wherein the mouthpiece element is arranged downstream of both the support element and the aerosol cooling element. Particularly preferably, the mouthpiece element is arranged directly downstream of the aerosol cooling element. As an example, the mouthpiece element may adjoin the downstream end of the aerosol cooling element.

The aerosol cooling element may, for example, form a plurality of longitudinally extending channels so as to provide a large surface area available for heat exchange. The plurality of longitudinally extending channels may be formed by a sheet material that has been pleated, gathered or folded to form channels. The plurality of longitudinally extending channels may be formed by one sheet that has been pleated, gathered or folded to form several channels. The sheet may also be corrugated before pleating, gathering or folding. The plurality of longitudinally extending channels may be formed by several sheets that have been corrugated, pleated, gathered or folded to form several channels. The plurality of longitudinally extending channels may be formed by multiple sheets that have been corrugated, pleated, gathered, or folded together, that is, two or more sheets that have been introduced into an overlapping arrangement and then corrugated, pleated, gathered, or folded as one.

One such aerosol cooling element may have a total surface area from approximately 300 square millimeters per millimeter of length to approximately 1000 square millimeters per millimeter of length.

One such aerosol cooling element preferably provides low resistance to air flow through the additional cooling element. Preferably, the aerosol cooling element does not substantially affect the draw resistance of the aerosol generating article. The aerosol cooling element preferably comprises a sheet material selected from the group consisting of a metal foil, a polymer sheet and substantially non-porous paper or cardboard. The aerosol cooling element may comprise a sheet of material selected from the group consisting of polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), polyethylene terephthalate (PET), polylactic acid (PLA), cellulose acetate (CA) and aluminum foil. The additional cooling element comprises a sheet of PLA.

The aerosol generating article may further comprise an upstream section at a location upstream of the aerosol generating element. The upstream section may comprise one or more upstream elements. The upstream section may comprise an upstream element located immediately upstream of the aerosol generating element.

The upstream element may provide an improved appearance to the upstream end of the aerosol-generating article. Additionally, if desired, the upstream element may be used to provide information about the aerosol-generating article, such as brand information, fragrance information, content information, or information about the aerosol-generating device with which the article is intended to be used.

The upstream element may be a porous element in the form of a plug. Preferably, the porous element in the form of a plug does not change the resistance to draw of the aerosol-generating article. Preferably, the upstream element has a porosity of at least about 50 percent in the longitudinal direction of the aerosol-generating article. More preferably, the upstream element has a porosity of from about 50 percent to about 90 percent in the longitudinal direction. The porosity of the upstream element in the longitudinal direction is determined by the ratio of the cross-sectional area of the material forming the upstream element and the internal cross-sectional area of the aerosol-generating article in the position of the upstream element.

The upstream element may be made of a porous material or may comprise a plurality of holes. This may be achieved, for example, by laser perforation. Preferably, the plurality of holes are uniformly distributed over the cross-section of the upstream element.

The porosity or permeability of the upstream element can be advantageously varied to provide the required overall draw resistance of the aerosol generating article.

Preferably, the RTD of the upstream element is at least about 5 millimeters of water column. More preferably, the RTD of the upstream element is at least about 10 millimeters of water column. Even more preferably, the RTD of the upstream element is at least about 15 millimeters of water column. The RTD of the upstream element may be at least about 20 millimeters of water column.

The RTD of the upstream element is preferably less than or equal to about 80 millimeters of water column. More preferably, the RTD of the upstream element is less than or equal to about 60 millimeters of water column. Even more preferably, the RTD of the upstream element is less than or equal to about 40 millimeters of water column.

The RTD of the upstream element may be from about 5 millimeters of water to about 80 millimeters of water, preferably from about 10 millimeters of water to about 80 millimeters of water, more preferably from about 15 millimeters of water to about 80 millimeters of water, even more preferably from about 20 millimeters of water to about 80 millimeters of water. The RTD of the upstream element may be from about 5 millimeters of water to about 60 millimeters of water, preferably from about 10 millimeters of water to about 60 millimeters of water, more preferably from about 15 millimeters of water to about 60 millimeters of water, even more preferably from about 20 millimeters of water. to about 60 millimeters of water column. The RTD of the upstream element may be from about 5 millimeters of water column to about 40 millimeters of water column, preferably from about 10 millimeters of water column to about 40 millimeters of water column, more preferably from about 15 millimeters of water column to about 40 millimeters of water column, even more preferably from about 20 millimeters of water column to about 40 millimeters of water column.

The upstream element may be formed from an air-impermeable material. The aerosol-generating article may be designed so that air flows into the aerosol-generating rod through suitable ventilation means provided in the wrapper.

The upstream element may be made of any material suitable for use in an aerosol-generating article. The upstream element may be made, for example, of the same material as is used for one of the other components of the aerosol-generating article, such as a mouthpiece, a cooling element, or a support element. Suitable materials for forming the upstream element include filter materials, ceramics, a polymeric material, cellulose acetate, cardboard, zeolite, or an aerosol-generating substrate. Preferably, the upstream element is formed from a cellulose acetate plug.

Preferably, the upstream element is formed from a heat-resistant material. For example, the upstream element is preferably formed from a material that can withstand temperatures of up to 350 degrees Celsius. This ensures that the upstream element is not adversely affected by the heating means intended for heating the aerosol-generating substrate.

Preferably, the element located upstream of the flow has a diameter that is approximately equal to the diameter of the aerosol generating article.

Preferably, the upstream element has a length of about 1 millimeter to about 10 millimeters, more preferably about 3 millimeters to about 8 millimeters, more preferably about 4 millimeters to about 6 millimeters. The upstream element may have a length of about 5 millimeters. The length of the upstream element can advantageously be varied to provide the desired overall length of the aerosol-generating article. For example, if it is necessary to reduce the length of one of the other components of the aerosol-generating article, the length of the upstream element can be increased to maintain the overall length of the article at the same level.

The upstream element preferably has a substantially uniform structure. For example, the upstream element may have a substantially uniform texture and appearance. The upstream element may, for example, have a continuous, level surface over its entire cross-section. The upstream element may, for example, have no recognizable symmetries.

The upstream element is preferably surrounded by a wrapper. The wrapper surrounding the upstream element is preferably a rigid filament, such as a filament having a basis weight of at least about 80 grams per square meter (g/ ^m2 ), or at least about 100 g/ ^m2 , or at least about 110 g/ ^m2 . This provides structural rigidity to the upstream element.

The aerosol generating article may have a length from approximately 35 millimeters to approximately 100 millimeters.

The aerosol generating article may have a length from approximately 35 millimeters to approximately 100 millimeters.

Preferably, the total length of the aerosol-generating article according to the present invention is at least about 38 millimeters. More preferably, the total length of the aerosol-generating article according to the present invention is at least about 40 millimeters. Even more preferably, the total length of the aerosol-generating article according to the present invention is at least about 42 millimeters.

The total length of the aerosol-generating article according to the present invention is preferably less than or equal to 70 millimeters. More preferably, the total length of the aerosol-generating article according to the present invention is preferably less than or equal to 60 millimeters. Even more preferably, the total length of the aerosol-generating article according to the present invention is preferably less than or equal to 50 millimeters.

The total length of the aerosol-generating article is preferably from about 38 millimeters to about 70 millimeters, more preferably from about 40 millimeters to about 70 millimeters, even more preferably from about 42 millimeters to about 70 millimeters. The total length of the aerosol-generating article is preferably from about 38 millimeters to about 60 millimeters, more preferably from about 40 millimeters to about 60 millimeters, even more preferably from about 42 millimeters to about 60 millimeters. The total length of the aerosol-generating article is preferably from about 38 millimeters to about 50 millimeters, more preferably from about 40 millimeters to about 50 millimeters, even more preferably from about 42 millimeters to about 50 millimeters. The total length of the aerosol generating product may be approximately 45 millimetres.

The aerosol generating article has an external diameter of at least 5 millimeters. Preferably, the aerosol generating article has an external diameter of at least 6 millimeters. More preferably, the aerosol generating article has an external diameter of at least 7 millimeters.

Preferably, the aerosol-generating article has an outer diameter that is less than or equal to approximately 12 millimeters. More preferably, the aerosol-generating article has an outer diameter that is less than or equal to approximately 10 millimeters. Even more preferably, the aerosol-generating article has an outer diameter that is less than or equal to approximately 8 millimeters.

The aerosol-generating article may have an outer diameter of about 5 millimeters to about 12 millimeters, preferably about 6 millimeters to about 12 millimeters, more preferably about 7 millimeters to about 12 millimeters. The aerosol-generating article may have an outer diameter of about 5 millimeters to about 10 millimeters, preferably about 6 millimeters to about 10 millimeters, more preferably about 7 millimeters to about 10 millimeters. The aerosol-generating article may have an outer diameter of about 5 millimeters to about 8 millimeters, preferably about 6 millimeters to about 8 millimeters, more preferably about 7 millimeters to about 8 millimeters.

An aerosol generating article according to the present invention comprises, in a linear sequential arrangement, an upstream element, an aerosol generating rod positioned immediately downstream of the upstream element, a support element positioned immediately downstream of the aerosol generating element, a mouthpiece element positioned immediately downstream of the support element, and an outer wrapper surrounding the upstream element, the aerosol generating element, the support element, and the mouthpiece element.

In more detail, the aerosol generating rod may be adjacent to an upstream element. The support element may be adjacent to the aerosol generating rod. The aerosol cooling element may be adjacent to the support element. The mouthpiece element may be adjacent to the aerosol cooling element.

The aerosol generating article has a substantially cylindrical shape and an outer diameter of approximately 7.25 millimeters.

The upstream element has a length of approximately 9 millimeters, the aerosol generating element has a length of approximately 12 millimeters, the support element has a length of approximately 18 millimeters, and the mouthpiece element has a length of approximately 8 millimeters. Thus, the total length of the aerosol generating article is approximately 47 millimeters.

The upstream element is in the form of a cellulose acetate plug wrapped in rigid fibreglass.

The aerosol generating rod comprises in a linear sequential arrangement a second aerosol generating segment comprising a plug made of a porous substrate and an aerosol generating gel as described above, provided in a core portion of the plug; a first aerosol generating segment comprising an assembled sheet of homogenised tobacco material; and a non-aerosol generating segment comprising a plug made of a porous substrate.

The mouthpiece is shaped as a filter segment made of low density cellulose acetate.

The aerosol generating rods and articles according to the present invention can be used in an aerosol generating device comprising a heater for heating the rod or the article. Thus, the present invention also relates to an aerosol generating system comprising one such aerosol generating device, such as an electrically heated aerosol generating device, and an aerosol generating article that comprises an aerosol generating rod as described above. Examples of suitable aerosol generating devices will be known to a person skilled in the art. In general, suitable aerosol generating devices will comprise a heating chamber for accommodating at least one aerosol generating article therein, and a heater adapted to heat at least one aerosol generating article when they are placed inside the chamber.

This includes, but is not limited to, aerosol generating devices comprising one or more induction heaters located around the periphery of a susceptor tubular element forming a heating chamber. Aerosol generating devices comprising other types of external heating elements may also be suitable.

Preferably, the aerosol generating article comprises a current collecting element. The current collecting element may be located inside the aerosol generating element or may surround the aerosol generating element.

As discussed above, the present invention also relates to an aerosol generating system comprising an aerosol generating device having a distal end and a mouth end. The aerosol generating device comprises a main part. The main part, or casing, of the aerosol generating device forms a cavity of the device for removably placing an aerosol generating article at the mouth end of the device. The aerosol generating device comprises a heating element or heater for heating an aerosol generating substrate when the aerosol generating article is placed within the cavity of the device.

The cavity of the device may be called the heating chamber of the aerosol generating device. The cavity of the device may extend between the distal end and the mouthpiece, or near end. The distal end of the cavity of the device may be a closed end, and the mouthpiece, or near end of the cavity of the device may be an open end. The aerosol generating article may be inserted into the cavity of the device, or the heating chamber, through the open end of the cavity of the device. The cavity of the device may have a cylindrical shape in order to match the same shape of the aerosol generating article.

The expression "housed within" may refer to the fact that a component or element is wholly or partially housed within another component or element. For example, the expression "an aerosol-generating article is housed within a cavity of a device" refers to an aerosol-generating article that is wholly or partially housed within a cavity of a device of an aerosol-generating article. When an aerosol-generating article is housed within a cavity of a device, the aerosol-generating article may abut a distal end of the cavity of the device. When an aerosol-generating article is housed within a cavity of a device, the aerosol-generating article may be in substantial proximity to a distal end of the cavity of the device. The distal end of the cavity of the device may be defined by an end wall.

The diameter of the cavity of the device may be the same as or larger than the diameter of the aerosol-generating article. The diameter of the cavity of the device may be the same as the diameter of the aerosol-generating article to form an interference fit with the aerosol-generating article.

The cavity of the device may be designed to form a press fit with an aerosol-generating article located inside the cavity of the device. The press fit may refer to a tight fit. The aerosol-generating device may comprise a peripheral wall. Such a peripheral wall may form a cavity of the device, or a heating chamber. The peripheral wall forming the cavity of the device may be designed to engage with the aerosol-generating article located inside the cavity of the device by means of a press fit, so that there is essentially no gap or empty space between the peripheral wall forming the cavity of the device and the aerosol-generating article when it is located inside the device.

Such a press fit may create an airtight fit or configuration between the cavity of the device and the aerosol generating article located therein.

With such an air-tight configuration, there will be essentially no gap or empty space between the peripheral wall forming the cavity of the device and the aerosol generating article for air to flow therethrough.

An interference fit with the aerosol generating article may be created along the entire length of the cavity of the device or along a portion of the length of the cavity of the device.

The aerosol generating device may comprise an air flow channel extending between the channel inlet and the channel outlet. The air flow channel may be configured to create a fluid communication between the interior of the cavity of the device and the exterior of the aerosol generating device. The air flow channel of the aerosol generating device may be formed inside the casing of the aerosol generating device to provide a fluid communication between the interior of the cavity of the device and the exterior of the aerosol generating device. When the aerosol generating article is placed inside the cavity of the device, the air flow channel may be adapted to provide an air flow into the article to deliver the generated aerosol to the user who takes a puff through the mouth end of the article.

The air flow channel of the aerosol generating device may be formed inside the peripheral wall of the casing of the aerosol generating device, or by this peripheral wall. In other words, the air flow channel of the aerosol generating device may be formed within the thickness of the peripheral wall, or by the inner surface of the peripheral wall, or by a combination of both. The air flow channel may be partially formed by the inner surface of the peripheral wall and may be partially formed within the thickness of the peripheral wall. The inner surface of the peripheral wall defines a peripheral boundary of the cavity of the device.

The air flow channel of the aerosol generating device may extend from an inlet located at the mouth end, or proximal end, of the aerosol generating device to an outlet located away from the mouth end of the device. The air flow channel may extend along a direction parallel to the longitudinal axis of the aerosol generating device.

The aerosol generating device may comprise an elongated heater (or heating element) designed to be inserted into the aerosol generating article when the aerosol generating article is placed within the cavity of the device. The elongated heater may be arranged with the cavity of the device. The elongated heater may extend into the cavity of the device. Additional arrangements for heating are discussed in more detail below.

The heater may be any suitable type of heater. Preferably, the heater is an external heater.

Preferably, the heater can externally heat the aerosol-generating article when it is placed inside the aerosol-generating device. Such an external heater can surround the aerosol-generating article when it is inserted into the aerosol-generating device or placed inside it.

The heater may be adapted to heat the outer surface of the aerosol-forming substrate. The heater may be positioned to be inserted into the aerosol-forming substrate when the aerosol-forming substrate is placed in the cavity. The heater may be positioned inside the cavity of the device, or a heating chamber.

The heater may comprise at least one heating element. The at least one heating element may be a heating element of any suitable type. The device may comprise only one heating element. The device may comprise a plurality of heating elements. The heater may comprise at least one resistive heating element. Preferably, the heater comprises several resistive heating elements. Preferably, the resistive heating elements are electrically connected in a parallel arrangement. Advantageously, providing several resistive heating elements electrically connected in a parallel arrangement may facilitate the delivery of the desired electrical power to the heater, while reducing or minimizing the voltage required to provide the desired electrical power. Advantageously, reducing or minimizing the voltage required to operate the heater may contribute to reducing or minimizing the physical size of the power supply.

Suitable materials for forming at least one resistive heating element include, but are not limited to: semiconductors such as doped ceramics, electrically "conductive" ceramics (such as, for example, molybdenum disilicide), carbon, graphite, metals, metal alloys, and composite materials made of a ceramic material and a metallic material. Such composite materials may comprise doped or undoped ceramics. Examples of suitable doped ceramics include doped silicon carbides. Examples of suitable metals include titanium, zirconium, tantalum, and platinum group metals. Examples of suitable metal alloys include stainless steel, nickel-, cobalt-, chromium-, aluminum-, titanium-, zirconium-, hafnium-, niobium-, molybdenum-, tantalum-, tungsten-, tin-, gallium-, manganese- and iron-based alloys, as well as nickel-, iron-, cobalt-, stainless steel-, Timetal®-, and iron-manganese-aluminum-based superalloys.

At least one resistive heating element may comprise one or more stamped parts made of an electrically resistive material, such as stainless steel. At least one resistive heating element may comprise a heating wire or filament, such as a wire made of Ni-Cr (nickel-chromium), platinum, tungsten or an alloy.

At least one heating element may comprise an electrically insulating substrate, wherein at least one resistive heating element may be provided on the electrically insulating substrate.

The electrically insulating substrate may comprise any suitable material. For example, the electrically insulating substrate may comprise one or more of paper, glass, ceramic, anodized metal, coated metal, and polyimide. Ceramic may comprise mica, aluminum oxide (Al2O3), or zirconium dioxide (ZrO2). Preferably, the electrically insulating substrate has a thermal conductivity that is less than or equal to about 40 watts per meter-Kelvin, preferably less than or equal to about 20 watts per meter-Kelvin, and ideally less than or equal to about 2 watts per meter-Kelvin.

The heater may comprise a heating element comprising a rigid electrically insulating substrate with one or more electrically conductive paths or wires located on its surface. The size and shape of the electrically insulating substrate may allow it to be inserted directly into the aerosol-forming substrate. If the electrically insulating substrate is not rigid enough, the heating element may comprise an additional amplifying means. Current may flow through one or more electrically conductive paths to heat the heating element and the aerosol-forming substrate.

The heater may comprise an induction heating device. The induction heating device may comprise an induction coil and a power supply configured to provide a high-frequency oscillating current to the induction coil. In the context of this document, "high-frequency oscillating current" means an oscillating current with a frequency of from about 500 kHz to about 30 MHz. The heater may advantageously comprise a DC-AC converter for converting a DC current supplied by a DC power supply into an AC current. The induction coil may be designed to generate a high-frequency oscillating electromagnetic field when receiving a high-frequency oscillating current from the power supply. The induction coil may be designed to generate a high-frequency oscillating electromagnetic field in a cavity of the device. The induction coil may substantially surround the cavity of the device. The induction coil may be located within the cavity of the device and be adapted to surround the aerosol-generating article after placement. The induction coil may extend at least partially along the length of the cavity of the device.

The heater may comprise an induction heating element. The induction heating element may be a current collector. In the context of this document, the term "current collector" refers to an element comprising a material that is capable of converting electromagnetic energy into heat. When the current collector is placed in an alternating electromagnetic field, the current collector heats up. The heating of the current collector may be the result of at least one of hysteresis losses and eddy currents induced in the current collector, depending on the electrical and magnetic properties of the current collector material.

The current-receiving element can be arranged so that when the aerosol-generating article is placed in the cavity of the aerosol-generating device, the oscillating electromagnetic field generated by the induction coil induces a current in the current-receiving element, which leads to heating of the current-receiving element. The aerosol-generating device is preferably capable of generating a fluctuating electromagnetic field having a magnetic field strength (field strength H) of 1 to 5 kiloamperes per meter (kA/m), preferably 2 to 3 kA/m, for example approximately 2.5 kA/m. The electrical aerosol-generating device is preferably capable of generating a fluctuating electromagnetic field having a frequency of 1 to 30 MHz, for example 1 to 10 MHz, for example 5 to 7 MHz.

The current-collecting element may be placed in an aerosol-generating article. The current-collecting element is preferably placed in contact with an aerosol-forming substrate. The current-collecting element may be placed in or inside the aerosol-forming substrate.

The current-collecting element may be located in the aerosol-generating device. The current-collecting element may be located in the cavity. The aerosol-generating device may contain only one current-collecting element. The aerosol-generating device may contain several current-collecting elements.

The current-collecting element may be adapted to heat the outer surface of the aerosol-forming substrate. The current-collecting element may be positioned to be inserted into the aerosol-forming substrate when the aerosol-forming substrate is positioned in the cavity.

The current collecting element may comprise any suitable material. The current collecting element may be formed from any material that can be inductively heated to a temperature sufficient to release volatile compounds from the aerosol-forming substrate. Suitable materials for the elongated current collecting element include graphite, molybdenum, silicon carbide, stainless steels, niobium, aluminum, nickel, nickel compounds, titanium, and composites of metallic materials. Some current collecting elements comprise metal or carbon. Advantageously, the current collecting element may comprise or consist of a ferromagnetic material, such as ferritic iron, a ferromagnetic alloy such as ferromagnetic steel or stainless steel, ferromagnetic particles, and ferrite. A suitable current collecting element may be made of or comprise aluminum. The current collecting element preferably comprises more than about 5 percent, preferably more than about 20 percent, more preferably more than about 50 percent or more than about 90 percent of ferromagnetic or paramagnetic materials. Some elongated current collecting elements can be heated to a temperature in excess of about 250 degrees Celsius.

The current collecting element may comprise a non-metallic core with a metallic layer located on the non-metallic core. For example, the current collecting element may comprise metallic tracks formed on the outer surface of a ceramic core or substrate.

The current-receiving element may comprise a current collector in the form of a sleeve for heating an aerosol-generating article, preferably an aerosol-generating element. The current-receiving element may form a chamber for accommodating the aerosol-generating article therein. The current-receiving element may surround at least a portion of the aerosol-generating article, when the article is placed inside the current-receiving element. The current-receiving element may surround at least an aerosol-generating element or substrate, when the article is placed inside the current-receiving element. The current-receiving element may comprise a tube. The current-receiving element may comprise a tube having a partially or completely porous wall. One or more induction coils are mounted around the current-receiving element or sleeve. A pair of induction coils are mounted around the current-receiving element or sleeve. The aerosol-generating article may not comprise an internal current collector.

The aerosol generating device may comprise at least one resistive heating element and at least one induction heating element. The aerosol generating device may comprise a combination of resistive heating elements and induction heating elements.

The aerosol generating system may also comprise a mouthpiece or tube that is connected to the aerosol generating device or aerosol generating article. The mouthpiece may comprise or be made of a hollow tube made of cardboard, plastic, polymer or paper material. The mouthpiece may be made of a biodegradable material. Once one or more aerosol generating articles or rods are inserted into the aerosol generating device, the aerosol generating rod or article may not be positioned in such a way that the user can directly inhale through it, especially if the aerosol generating article comprises only an aerosol generating rod and does not comprise a mouthpiece filter or downstream section at all. Instead, the user may connect or attach a separate mouthpiece to either the downstream end of the aerosol generating rod, which is exposed at the open end of the cavity of the device, or to the open proximal end of the cavity of the device. Such a mouthpiece or tube will direct the generated aerosol toward the user.

The aerosol generating system may comprise a plurality of aerosol generating articles, and the heating device or aerosol generating device is adapted to accommodate one or more of the plurality of aerosol generating articles. As mentioned above, the heating device may be adapted to accommodate at least two aerosol generating articles simultaneously. The user may insert into the heating device or aerosol generating device different, relatively short rods or aerosol generating articles, each of which has a different type of aerosol generating element, in order to advantageously modify the final aerosol created or captured in the air flowing through the different aerosol generating rods. The aerosol generating device may comprise one heater or more than one heater, one heater for each aerosol generating article that the device is adapted to accommodate.

The present invention is defined in the claims. However, a non-exhaustive list of non-limiting examples is provided below. 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:

Example 1. An aerosol-generating article for producing an inhalable aerosol upon heating, wherein the aerosol-generating article comprises:

first segment;

the second segment, wherein the second segment is permeable;

an aerosol generating element located between the first segment and the second segment, wherein the second segment is located further downstream of the aerosol generating element; and

a wrapper surrounding the first segment, the aerosol generating element, and the second segment, wherein the portion of the wrapper surrounding the aerosol generating element is breathable such that the wrapper provides fluid communication between the outer portion of the aerosol generating article and the aerosol generating element.

Example 2. An aerosol generating article according to example 1, wherein the first segment is a first segment in the form of a plug.

Example 3. An aerosol generating article according to example 1 or 2, wherein the second segment is a second segment in the form of a plug.

Example 4. An aerosol generating article according to any of the previous examples, wherein the aerosol generating element is located downstream of the first segment.

Example 5. An aerosol generating article according to any of the previous examples, wherein the aerosol generating element is located immediately downstream of the first segment.

Example 6. An aerosol generating article according to any of the previous examples, wherein the second segment is located immediately downstream of the aerosol generating element.

Example 7. An aerosol generating article according to any of the previous examples, wherein the aerosol generating element is located directly between the first segment and the second segment.

Example 8. An aerosol generating article according to any of the previous examples, wherein the first segment is a first filter segment.

Example 9. An aerosol generating article according to any of the previous examples, wherein the second segment is a second filter segment.

Example 10. An aerosol generating article according to any of the previous examples, wherein the air permeability of the permeable portion of the wrapper is at least 2500 Coresta units.

Example 11. An aerosol generating article according to any of the previous examples, wherein the air permeability of the permeable portion of the wrapper is at least 5000 Coresta units.

Example 12. An aerosol generating article according to any of the previous examples, wherein at least 50 percent of the portion of the wrapper surrounding the aerosol generating element is air permeable.

Example 13. An aerosol generating article according to any of the previous examples, wherein the basis weight of the wrapper is at least 10 grams per square meter (g/ ^m2 ).

Example 14. An aerosol generating article according to any one of examples 1 to 10, wherein the air permeability of the permeable portion of the wrapper is at least 2500 Coresta units, preferably at least 5000 Coresta units, and wherein at least 50 percent of the portion of the wrapper surrounding the aerosol generating element is air permeable.

Example 15. An aerosol generating article according to any of the previous examples, wherein the entire portion of the wrapper surrounding the aerosol generating element is breathable.

Example 16. An aerosol generating article according to any of the previous examples, wherein the aerosol generating element is visible through the wrapper.

Example 17. An aerosol generating article according to any of the previous examples, wherein the portion of the wrapper surrounding the aerosol generating element is translucent or transparent.

Example 18. An aerosol generating article according to example 17, wherein the light transmittance of the portion of the wrapper surrounding the aerosol generating element is at least 40 percent, preferably at least 50 percent.

Example 19. An aerosol generating article according to any of the previous examples, wherein the first segment in the form of a plug is impermeable.

Example 20. An aerosol generating article according to any of examples 1 to 17, wherein the first segment in the form of a plug is permeable.

Example 21. An aerosol generating article according to example 20, wherein the resistance to draw (RTD) per unit length of the first plug-shaped segment is from about 0 mm H2O per mm to about 3 mm H2O per mm.

Example 22. An aerosol generating article according to any of the previous examples, wherein the RTD per unit length of the second plug segment is from about 0 mm H2O per mm to about 3 mm H2O per mm.

Example 23. An aerosol-generating article according to any of the previous examples, additionally comprising a current-collecting element, wherein the current-collecting element is located inside the aerosol-generating element or surrounds the aerosol-generating element.

Example 24. An aerosol generating article according to any of the previous examples, wherein the aerosol generating element comprises tobacco material and an aerosol forming substance.

Example 25. An aerosol generating article according to example 24, wherein the tobacco material comprises one or more of homogenized tobacco material, tobacco molded sheet, and reconstituted tobacco.

Example 26. An aerosol generating article according to any of the previous examples, wherein the aerosol generating element comprises non-tobacco plant material.

Example 27. An aerosol generating article according to any of examples 1 to 23, wherein the aerosol generating element comprises a porous substrate impregnated with a liquid or gel.

Example 28. An aerosol generating article according to example 24, wherein the gel comprises an alkaloid compound, an aerosol forming substance and at least one gelling agent.

Example 29. An aerosol-generating article according to any of the previous examples, wherein the wrapper is impregnated with a flavoring agent.

Example 30. An aerosol generating article according to any of the previous examples, wherein the length of the first plug segment or the second plug segment is from 2 millimeters to 10 millimeters.

Example 31. An aerosol generating article according to any of the previous examples, wherein the length of the aerosol generating element is from 5 millimeters to 25 millimeters.

Example 32. An aerosol generating system comprising an aerosol generating article according to any of the previous examples and a heating device adapted to accommodate the aerosol generating article therein.

Example 33. An aerosol generating system according to example 32, wherein the heating device is configured to heat the aerosol generating article from the outside when it is placed inside the aerosol generating device.

Example 34. An aerosol generating system according to example 32 or 33, further comprising a mouthpiece element connectable to an aerosol generating device or an aerosol generating article.

Example 35. An aerosol generating system according to any one of examples 32 to 34, comprising a plurality of aerosol generating articles, each according to any one of examples 1 to 31, wherein the heating device is adapted to accommodate one or more of the plurality of aerosol generating articles.

Example 36. An aerosol generating system according to example 35, wherein the heating device is adapted to accommodate one aerosol generating article or two aerosol generating articles simultaneously.

In the following paragraphs, the present invention will be further described with reference to the accompanying drawings, in which:

Fig. 1 is a schematic side perspective view of a partially deployed aerosol generating article according to an embodiment of the present invention;

Fig. 2 is a schematic side perspective view of another partially deployed aerosol generating article in accordance with an alternative embodiment of the present invention;

Fig. 3 is a schematic cross-sectional side view of another aerosol generating article in accordance with an alternative embodiment of the present invention;

Fig. 4 is a schematic side sectional view of another aerosol generating article in accordance with an alternative embodiment of the present invention; and

Fig. 5 is a schematic side cross-sectional view of an aerosol generating system in accordance with the present disclosure.

An embodiment of the article or rod 1 generating an aerosol is shown in Fig. 1. The rod 1 generating an aerosol comprises a first segment 2 located earlier in the flow direction in the form of a plug and an aerosol generating element 4 located immediately further in the flow direction relative to the first segment 2 in the form of a plug. The second segment 6 located further in the flow direction in the form of a plug is located immediately further in the flow direction relative to the element 4 generating an aerosol. In fact, two segments 2, 6 in the form of a plug adjoin the aerosol generating element 4 on the sides.

The first segment 2 in the form of a plug, the element 4 generating the aerosol, and the second segment 6 in the form of a plug are in a linear sequential arrangement and in axial alignment. The first segment 2 in the form of a plug extends from the end 3 of the rod 1 generating the aerosol located upstream to the end of the element 4 generating the aerosol located upstream, and the second segment 6 in the form of a plug extends from the end of the element 4 generating the aerosol located downstream to the end of the rod 1 generating the aerosol located downstream. The first segment 2 in the form of a plug, the element 4 generating the aerosol, and the second segment 6 in the form of a plug are adjacent to each other.

The aerosol generating rod 1 shown in Fig. 1 and Fig. 2 comprises a wrapper 8 having a permeable portion or section 12. The wrapper 8 surrounds a first segment 2 in the form of a plug, an aerosol generating element 4, and a second segment 6 in the form of a plug. The permeable portion 12 of the wrapper 8 is made of tea bag material.

As shown in Fig. 1, the permeable portion 12 of the wrapper 8 extends across and along that portion of the wrapper 8 which is adapted to overlap or surround the aerosol generating element 4. The permeable portion 12 is adapted to cover the entire outer surface of the aerosol generating element 4.

As shown in the alternative arrangement of Fig. 2, the permeable portion 12 occupies the entire surface area of the wrapper 8 and is not limited to a specific area of the wrapper 8.

The contents of the aerosol generating rod 1 (at least the aerosol generating element 4) are visible through the permeable portion 12 of the wrapper 8.

The air permeability of the permeable portion 12 of the wrapper 8 is approximately 5000 Coresta units. The air permeability of the wrapper 8 is approximately 5000 Coresta units. The basic weight of the wrapper 8 is approximately 15 grams per square meter.

The aerosol generating rod 1 comprises a first plug segment which is non-porous or impermeable such that air cannot enter the rod 1 through the upstream end 3. Air can flow, as shown by arrows B, into the aerosol generating element 4 only through the permeable portion 12 of the wrapper 8. The generated aerosol can then flow out of the aerosol generating element 4 through the second plug segment 6 and exit from the downstream end 5 of the aerosol generating rod 1 as shown by arrow C. Although arrows B are shown in the upper part of Fig. 3, air can enter the aerosol generating rod 1 from any direction through the permeable portion 12. The RTD per unit length of the second plug segment is approximately 3 mm H2O per mm.

An alternative embodiment of the aerosol generating rod 11 is shown in Fig. 4, which differs from the aerosol generating rod 1 shown in Fig. 3 in that the first plug segment 22 is air-permeable to allow air to also enter the aerosol generating rod 11 through the upstream end 3, as indicated by the arrows A. The RTD per unit length of the first plug segment is approximately 3 mm H2O per mm.

The first segment 2, 22 in the form of a plug has a length of approximately 5 millimeters. The element or segment 4, generating an aerosol, has a length of approximately 10 millimeters. The second segment 6 in the form of a plug has a length of approximately 5 millimeters. Thus, the rod 1, 11, generating an aerosol, has a total length of approximately 20 millimeters. The outer diameter of the rod 1, 11, generating an aerosol is approximately 7.25 millimeters.

The first and second segments 22, 6 in the form of a plug are made of a permeable filter material, such as a cellulose acetate tow. The aerosol generating element 4 contains a tobacco material and an aerosol forming substance. In more detail, the aerosol generating element 4 contains an assembled sheet of homogenized tobacco material. Alternatively, the aerosol generating element 4 contains a porous substrate impregnated with a liquid or gel. The aerosol generating element 4 preferably contains a current collecting element (not shown) located inside it.

Fig. 5 schematically shows an electrically controlled aerosol generating system 100, comprising an aerosol generating device 10, an aerosol generating rod or article 11, and a detachable mouthpiece segment 18. Fig. 5 shows a downstream portion of the mouthpiece end of the aerosol generating device 10, where a cavity of the device is formed and the aerosol generating article 10 can be accommodated. The aerosol generating device 1 comprises a housing (or main part) extending between the mouthpiece end and a distal end (not shown). The housing comprises a peripheral wall 14. The peripheral wall 14 defines a cavity of the device for accommodating the aerosol generating article 11 therein. The cavity of the device is defined by a closed distal end and an open mouthpiece end. The mouthpiece end of the cavity of the device is placed on the mouthpiece end of the aerosol-generating device 10. The aerosol-generating article 11 is designed with the possibility of placement through the mouthpiece end of the cavity of the device.

An illustrative aerosol generating device 10 comprises an induction heater having one or more external induction coils (not shown) and a current collector in the form of a sleeve 16 for heating an aerosol generating article 11, in particular an aerosol generating element 4. The current collector in the form of a sleeve 16 comprises a tube having a porous wall. One or more induction coils (not shown) are mounted around the current collector in the form of a sleeve 16, which forms a cylindrical chamber for accommodating the aerosol generating article 11 therein, as schematically shown in Fig. 5.

The aerosol generating device 10 is powered by a battery (not shown) and is controlled by a control circuit or electronics (not shown). The user can connect the mouthpiece segment 18, which contains a hollow tube made of cardboard material, to the downstream end 5 of the aerosol generating rod 1, 11, in order to direct the generated aerosol into the user's mouth when taking a puff.

It will be understood that the aerosol generating rod or article 1, 11 described above may also be suitable for use with other aerosol generating devices.

For the purposes of the present specification and the appended claims, except where otherwise indicated, all numbers expressing quantities, amounts, percentages, etc., are to be understood as modified in all instances by the term "about". Also, all ranges include the disclosed maximum and minimum points and include any intermediate ranges therebetween that may or may not be specifically listed herein. Therefore, in this context, the number A is understood to be A ± 10% of A. In this context, the number A may be considered to include numerical values that are within the normal standard error for measuring the property that the number A modifies. The number A, in some instances, when used in the appended claims, may vary by the percentages listed above, provided that the amount by which A varies does not materially affect the fundamental and novel characteristic(s) of the claimed invention. Also, all ranges include the disclosed maximum and minimum points and include any intermediate ranges therebetween that may or may not be specifically listed herein.

Claims (19)

1. An aerosol-generating article for producing an inhalable aerosol upon heating, wherein the aerosol-generating article comprises: a first segment in the form of a plug containing a solid cross-section of material; a second plug-shaped segment comprising a continuous cross-section of material, wherein the second plug-shaped segment is a filter plug-shaped segment and is permeable; an aerosol generating element located directly between the first plug segment and the second plug segment, wherein the second plug segment is located further downstream of the aerosol generating element; and a wrapper surrounding the first plug-shaped segment, the aerosol-generating element, and the second plug-shaped segment, wherein the portion of the wrapper surrounding the aerosol-generating element is air-permeable such that the wrapper provides fluid communication between the exterior of the aerosol-generating article and the aerosol-generating element, and wherein the air permeability of said permeable portion of the wrapper is greater than 2,500 Coresta units and less than 12,000 Coresta units. 2. An aerosol generating article according to claim 1, wherein the air permeability of the permeable portion of the wrapper is at least 5000 Coresta units. 3. An aerosol-generating article according to any of the preceding claims, wherein the basis weight of the wrapper is at least 10 grams per square metre (g/ ^m2 ). 4. An aerosol generating article according to any of the preceding claims, wherein at least 50% of the portion of the wrapper surrounding the aerosol generating element is air permeable. 5. An aerosol generating article according to any of the preceding claims, wherein the entire portion of the wrapper surrounding the aerosol generating element is air permeable. 6. An aerosol generating article according to any of the preceding claims, wherein the aerosol generating element is visible through the wrapper. 7. An aerosol-generating article according to any of the preceding claims, wherein a portion of the wrapper surrounding the aerosol-generating element is translucent or transparent. 8. An aerosol generating article according to claim 7, wherein the light transmittance of the portion of the wrapper surrounding the aerosol generating element is at least 40%, preferably at least 50%. 9. An aerosol generating article according to any of the preceding claims, wherein the first plug-shaped segment is impermeable. 10. An aerosol generating article according to any one of claims 1 to 8, wherein the first segment in the form of a plug is permeable. 11. The aerosol generating article of claim 10, wherein the resistance to draw (RTD) per unit length of the first plug segment is from about 0 mm H2O per mm to about 3 mm H2O per mm. 12. An aerosol generating article according to any one of the preceding claims, wherein the RTD per unit length of the second plug segment is from about 0 mm H2O per mm to about 3 mm H2O per mm. 13. An aerosol generating article according to any of the preceding claims, wherein the length of each of the first and second plug segments is less than or equal to 5 mm. 14. An aerosol generating article according to any one of the preceding claims, wherein the second segment in the form of a plug is formed from a cellulosic material, a material based on polylactic acid, a bioplastic material or a sheet of material formed from paper, cardboard or a polymer. 15. An aerosol generating system comprising an aerosol generating article according to any one of the preceding claims and a heating device adapted to accommodate the aerosol generating article therein, wherein the heating device is preferably configured to heat the aerosol generating article from the outside when it is accommodated within the heating device.