RU2846005C1 - Aerosol-generating article having wrapper comprising embossed portion - Google Patents

Abstract

FIELD: smoking accessories.

SUBSTANCE: group of inventions relates to an aerosol-generating article and a method for manufacturing same. Aerosol-generating article comprises: a plurality of segments assembled together in a longitudinal direction, said plurality of segments including a rod of an aerosol-generating substrate; and a paper wrapper wrapped around said rod of aerosol-generating substrate and at least one of said plurality of segments. Paper wrap comprises embossed part that surrounds core of aerosol-generating substrate on at least 80 percent of core length and has basic weight of 50 g to 100 g per square meter. Inner surface of paper wrap comprises a layer of glue, wherein said layer of glue surrounds at least two of said plurality of segments to hold said at least two segments in place relative to each other.

EFFECT: said embossing and its disclosed length along the length of the rod are used in the invention as a means for effectively reducing the transfer of moisture/heat from the substrate to the wrapper.

15 cl, 9 dwg, 3 tbl

Description

The present invention relates to aerosol-generating articles having a wrapper. The present invention is particularly applicable to aerosol-generating articles containing an aerosol-generating substrate and adapted to produce an inhalable aerosol upon heating.

Combustible aerosol-generating articles such as cigarettes typically contain a cylindrical rod of shredded tobacco filler surrounded by a wrapper and a cylindrical filter axially aligned and adjacent to the wrapped tobacco rod. The cylindrical filter typically contains filter material surrounded by a wick. The wrapped tobacco rod and filter are connected by a band of rim wrap, usually made of paper material, that encircles the entire length of the filter and the adjacent portion of the tobacco rod. The consumer uses the cigarette by lighting one end of it, burning the shredded tobacco rod. The smoker then takes the main stream of smoke into his or her mouth by inhaling on the filter-containing end of the cigarette.

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 aerosol generating articles, the aerosol is formed by transferring heat from a heat source to, in, around, or downstream of a physically separate aerosol generating substrate or a material that may be in contact with the heat source. During use of the aerosol generating article, volatile compounds are released from the aerosol generating substrate by transferring heat 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 heater 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-receiving (=susceptor) element, located within the aerosol generating substrate.

It is generally known that one or more segments of an aerosol-generating article, such as an aerosol-generating substrate, are wrapped in a wrapper. The wrapper may help to hold one or more segments of the aerosol-generating article, such as an aerosol-generating substrate, in place. The wrapper may also provide a barrier between one or more segments of the aerosol-generating article, such as an aerosol-generating substrate, and the user. It is generally known that one or both of a thick wrapper and a wrapper with a high basis weight may be more effective in providing these and other desirable effects for an aerosol-generating article. However, one or both of a thick wrapper and a wrapper with a high basis weight may cause difficulties during manufacturing and assembly.

It would therefore be desirable to provide a wrapper that is sufficient to hold one or more segments of an aerosol-generating article, such as an aerosol-generating substrate, in place while being suitable for high-speed manufacturing. There is currently a limitation in the variety of materials and properties of wrappers that can be used for such purposes. It would also be desirable to minimize the interaction between the wrapper and the aerosol-generating substrate, as this in turn minimizes the interaction between the user and the aerosol-generating substrate.

The present invention relates to an aerosol-generating article. The aerosol-generating article may comprise a rod of an aerosol-generating substrate. The rod of an aerosol-generating substrate may comprise an aerosol-forming substance. The rod of an aerosol-generating substrate may have an aerosol-forming substance content of at least approximately 5 percent based on dry weight. The aerosol-generating article may comprise a paper wrapper wrapped around at least a portion of the aerosol-generating article. The paper wrapper may comprise an embossed portion. The paper wrapper may have a basis weight of at least 50 grams per square meter. The paper wrapper may have a basis weight of no more than 100 grams per square meter. Preferably, the paper wrapper has a basis weight of 50 grams per square meter to 100 grams per square meter.

According to the present invention, an aerosol-generating article is provided, wherein the aerosol-generating article comprises: a rod made of an aerosol-generating substrate; and a paper wrapper wrapped around at least a portion of the aerosol-generating article, wherein the paper wrapper comprises an embossed portion and has a basis weight of from 50 grams per square meter to 100 grams per square meter.

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. In the context of this document, the term "aerosol-generating substrate" means 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. By comparison, 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 heater plate which is adapted to be inserted into a rod of a substrate generating the 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 heating element that interacts with an aerosol generating substrate of an aerosol generating article to generate an aerosol.

In the context of this document, the term "basis weight" is a measure of mass per unit area in grams per square meter. In other words, basis weight is a measure of areal density. Basis weight may also be referred to as mass per square meter.

In the context of this document with reference to the present invention, the term "rod" is used to denote a generally cylindrical element of substantially circular, oval or elliptical cross-section.

The terms "distal", "upstream", "near" and "downstream" are used to describe the relative positions of components or parts of components of an aerosol-generating article. An aerosol-generating article according to the present invention has a near end through which, in use, the aerosol exits the article for delivery to the user, and has an opposite distal end. The near end of the aerosol-generating article may also be referred to as a mouthpiece end. In use, the user draws on the near end of the aerosol-generating article to inhale the aerosol generated by the aerosol-generating article. The terms upstream and downstream are provided with respect to the direction of movement of the aerosol through the aerosol-generating article when the user draws on the near end.

In the context of this document, the term "longitudinal" refers to the direction corresponding to the major longitudinal axis of the aerosol generating article, which passes between the upstream and downstream ends of the aerosol generating article.

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 may be used to refer to the longitudinal dimension of a rod or elongated tubular elements.

The terms "wrapper" or "paper wrapper" are used interchangeably and refer to a wrapping material that surrounds one or more segments of an aerosol-generating article to maintain the shape of the aerosol-generating article. And the wrapping material is made of paper and optional filler materials.

In the context of this document, with respect to a wrapper, the terms "inner" and "outer" when describing surfaces of the wrapper refer to the orientation of the wrapper relative to the component or segment of the aerosol-generating article around which the wrapper is wrapped. The wrapper may be wrapped such that the inner surface of the wrapper faces the said component or segment of the aerosol-generating article and the outer surface faces away from the said component or segment of the aerosol-generating article.

The term "bulge" is used in this document to refer to projections formed on the surface of the wrapper. These projections may be cut, molded, or stamped into the wrapper. The portion of the wrapper that has such bulges is called embossed. Sections of the wrapper that do not form bulges or protrude from the wrapper are referred to in this document as "concavities."

In the context of this document, the term "water resistant" refers to a wrapper that has moisture-resistant properties. One commonly used method for determining this property is by measuring the water contact angle. The "water contact angle" is the angle, usually measured through a liquid, where the liquid interface meets a solid surface. It is quantified as the wettability of the solid surface by the liquid according to Young's equation. Hydrophobicity or water contact angle can be determined using TAPPI Test Method T558 and the result is reported as the contact angle at the interface and is given in "degrees" and can range from close to zero to close to 180 degrees.

The paper wrapper according to the present invention provides an improved component for an aerosol-generating article. By providing a wrapper with a high basis weight, the interaction between one or more segments of the aerosol-generating article and the outer surface of the wrapper can be reduced. For example, a wrapper with a high basis weight can reduce the degree to which moisture can be transferred between one or more segments of the aerosol-generating article and the outer surface of the wrapper. This can also advantageously help to reduce the degree to which heat can be transferred between the aerosol-generating substrate and the wrapper.

The high basis weight wrapper of the present invention may also advantageously contribute to reducing the extent to which heat may be transferred between one or more segments of the aerosol-generating article and an aerosol-generating device used with the aerosol-generating article. This is particularly advantageous when the aerosol-generating substrate is heated by a heat source within the aerosol-generating substrate, such as one or both of the susceptor element and the heating plate, and when at least a portion of the aerosol-generating device surrounds a portion of the aerosol-generating article containing the aerosol-generating substrate. Such advantages may also be desirable when a rod of the aerosol-generating substrate is heated by a heating element upstream of the aerosol-generating substrate.

The insulating properties of a high basis weight wrap around one or more segments of the aerosol generating article may be advantageous from an energy efficiency perspective, such as by preventing unwanted heat loss from the aerosol generating article.

By providing a wrapper with a high basis weight around at least a portion of the aerosol-generating article, the structural integrity of the aerosol-generating article can be better maintained. In addition, a wrapper with a high basis weight can improve one or both of the tactile characteristics and the appearance of the aerosol-generating article, for example, by making the aerosol-generating article feel harder to the touch. This is because a wrapper with a high basis weight is itself stronger than a traditional wrapper, and can also be more resistant to one or both of moisture and heat from a heated aerosol-generating article. Therefore, the aerosol-generating article is less likely to deform during use.

By providing a wrapper with a high basis weight with an embossed portion, it is possible to wrap the wrapper with a high basis weight around one or more segments of the aerosol-generating article, and at the same time ensure the possibility of high-speed production of the aerosol-generating article. This is because the embossing on the wrapper can counteract the difficulties associated with the production of aerosol-generating articles with wrappers with a high basis weight. In particular, the embossing on the wrapper can give the wrapper with a high basis weight the same bending and twisting properties as the traditional wrapper. This can reduce the possibility of jamming of the production machine due to the defect caused by the wrapper. In addition, it can also reduce the possibility of defects on the wrapper being distinguishable after the assembly of the aerosol-generating article.

By providing the wrapper with an embossed portion, the interaction between the inner surface of the wrapper and one or more segments of the aerosol-generating article can be reduced. For example, the embossed portion can reduce the amount of contact between the inner surface of the wrapper and one or more segments of the aerosol-generating article. This can advantageously contribute to reducing the degree to which moisture can be transferred between one or more segments of the aerosol-generating article and the wrapper. This can also advantageously contribute to reducing the degree to which heat can be transferred between one or more segments of the aerosol-generating article and the wrapper.

The configuration of the wrapper according to the present invention may also advantageously contribute to reducing the degree to which heat may be transferred between one or more segments of the aerosol-generating article and an aerosol-generating device used with the aerosol-generating article. This is particularly advantageous when one or more segments of the aerosol-generating article are heated by a heat source within one or more segments of the aerosol-generating article, such as one or both of the susceptor element and the heating plate, and when at least a portion of the aerosol-generating device surrounds a portion of the aerosol-generating article containing the aerosol-generating substrate. Such advantages may also be desirable when the rod of the aerosol-generating substrate is heated by the heating element upstream of the aerosol-generating substrate.

The insulating properties of the embossed portion of the wrapper may be advantageous from an energy efficiency perspective, for example by preventing unwanted heat loss from the aerosol generating product.

By providing a wrapper with an embossed portion surrounding at least the aerosol-generating substrate rod, it is possible to wrap a thicker wrapper around the aerosol-generating substrate rod while maintaining the ability to manufacture an aerosol-generating article at a high speed. This is because the convexities on the wrapper can give the thicker wrapper the same bending and twisting properties as a normal wrapper.

By providing a thicker wrapper around one or more segments of the aerosol-generating article (such as the aerosol-generating substrate rod), the structural integrity of the aerosol-generating article can be maintained. This is because a thicker wrapper can be more resistant to one or both of the moisture and heat emanating from one or more segments of the aerosol-generating article, such as the aerosol-generating substrate rod. Therefore, the aerosol-generating article is less likely to become deformed during use.

In addition, by providing a thick wrapper with an embossed portion, the structural integrity of the aerosol-generating article can be further improved. This is because the reduced interaction between the aerosol-generating substrate and the wrapper, as discussed above, further reduces the likelihood of deformation of the aerosol-generating article during use.

Reduced interaction between the outer surface of the wrapper and one or more segments of the aerosol generating article (such as a rod of aerosol generating substrate) may also help reduce the likelihood of transferring one or both of moisture and heat to the outer surface of the wrapper.

The aerosol-generating article may have a paper wrapper wrapped around at least a portion of the aerosol-generating article. The wrapper may have a basis weight that is greater than conventional aerosol-generating article wrappers known in the art. A wrapper with a higher basis weight may act as an improved barrier between one surface of the wrapper and another surface of the wrapper. A wrapper with a higher basis weight may slow down or reduce the transmission of one or both of moisture and heat through the wrapper. This may help maintain the structural integrity of the wrapper and the aerosol-generating article. The paper wrapper may have a basis weight of 50 grams per square meter to 100 grams per square meter.

The aerosol generating article may comprise multiple segments or components. Multiple segments or components may be assembled together in a longitudinal direction. Multiple segments may be assembled in the form of a rod. Multiple segments may include a rod of aerosol generating substrate. A plurality of segments may include one or more of the following components, each of which is described in more detail below: an upstream element, a mouthpiece element, a support element, and an aerosol cooling element. Multiple segments may include one or both of a cavity and a filter segment. The filter segment may be a plug of fibrous filter material, such as cellulose acetate. The filter segment may be a hollow tube of fibrous filter material, such as a hollow acetate tube.

As noted above, the aerosol-generating article may comprise a paper wrapper wrapped around at least a portion of the aerosol-generating article. Accordingly, the paper wrapper may be wrapped around one or more segments or components of the aerosol-generating article, such as one or more of the aerosol-forming substrate rod, the upstream element, the mouthpiece element, the support element, the aerosol-cooling element, the filter segment, and the cavity. In some embodiments, the paper wrapper is wrapped around all segments of the aerosol-generating article. In some embodiments, the paper wrapper is wrapped around only some of the segments of the aerosol-generating article. Preferably, the paper wrapper is wrapped around at least two segments of the aerosol-generating article. Preferably, the paper wrapper is wrapped around the aerosol-generating substrate rod and at least one other segment of the aerosol-generating article.

The wrapper may be in the form of a sheet of paper. The wrapper may be essentially a rectangular sheet of paper. The wrapper may have an inner surface and an outer surface.

In a preferred embodiment, the wrapper is wrapped around at least a portion of the aerosol-generating substrate rod. Preferably, the wrapper is wrapped around the entire aerosol-generating substrate rod. Advantageously, providing the wrapper around at least a portion of the aerosol-generating substrate rod can reduce the migration of one or both of heat or moisture from the aerosol-generating substrate into the wrapper.

Preferably, the paper wrapper may have a basis weight of at least 60 grams per square meter. Preferably, the paper wrapper may have a basis weight of less than or equal to 90 grams per square meter. Preferably, the paper wrapper has a basis weight of 60 grams per square meter to 90 grams per square meter. In a preferred embodiment, the paper wrapper has a basis weight of less than or equal to 70 grams per square meter. Preferably, the paper wrapper has a basis weight of 60 grams per square meter to 70 grams per square meter. In another preferred embodiment, the paper wrapper has a basis weight of less than at least 75 grams per square meter. Preferably, the paper wrapper has a basis weight of less than or equal to 80 grams per square meter. Preferably, the paper wrapper has a basis weight of 75 grams per square meter to 80 grams per square meter.

As noted above, the wrapper may comprise an embossed portion. The embossed portion may surround at least a rod of aerosol-generating substrate. The embossed portion may surround only the rod of aerosol-generating substrate. The embossed portion may surround the rod of aerosol-generating substrate and one or more other parts of the aerosol-generating article, such as one or more other parts of the aerosol-generating article that are adjacent to the rod of aerosol-generating substrate. These other parts or components of the aerosol-generating article are described in more detail below and include, but are not limited to: an upstream element and components of a downstream section, including a mouthpiece element, a support element, and an aerosol cooling element.

The embossed portion of the wrapper may be a water-resistant wrapper. The water-resistant wrapper may provide an additional barrier against moisture from the aerosol-generating substrate rod. The embossed portion may have an inner surface that is water-resistant. In cases where the inner surface of the embossed portion of the wrapper is water-resistant, moisture from the aerosol-generating substrate rod may be prevented from penetrating into the wrapper. This may help reduce one or more of swelling, visible contamination, and physical weakening of the wrapper. It may also help maintain the structural integrity of the aerosol-generating article. Reducing or preventing swelling of the aerosol-generating article may improve the usability of the aerosol-generating article by allowing the aerosol-generating article to be reliably inserted and removed from the heating device with a reduced risk of damage to the aerosol-generating article.

One useful method for determining the water-resistant properties of a wrapper is to measure the water contact angle. The "water contact angle" is the angle, typically measured by a liquid, where the liquid/vapor interface meets a solid surface. In quantitative terms, it indicates the wettability of a solid surface by a liquid according to Young's equation. Hydrophobicity or water contact angle can be determined using TAPPI Test Method T558 and the result is reported as the contact angle at the interface and is indicated in "degrees" and can vary from close to zero to close to 180 degrees. The water-resistant inner surface of the embossed portion of the wrapper may have a water contact angle of at least 30 degrees. Preferably, the water-resistant inner surface of the embossed portion of the wrapper has a water contact angle of at least 40 degrees. It is more preferable that the water-resistant inner surface of the embossed portion of the wrapper has a water contact angle of at least 45 degrees.

The embossed portion of the wrapper may directly surround one or more segments of the aerosol-generating article, such as a rod of aerosol-generating substrate. Where the embossed portion of the wrapper directly surrounds one or more segments of the aerosol-generating article, such as a rod of aerosol-generating substrate, the embossed portion of the wrapper is in direct contact with the one or more segments of the aerosol-generating article.

The embossed portion of the wrapper may indirectly surround one or more segments of the aerosol-generating article, such as a rod of aerosol-generating substrate. Where the embossed portion of the wrapper indirectly surrounds one or more segments of the aerosol-generating article, one or more additional layers may be located between the embossed portion of the wrapper and the one or more segments of the aerosol-generating article. The one or more additional layers may be formed by one or more additional wrappers.

The embossed portion of the wrapper may surround one or more segments of the aerosol generating article around the entire circumference of the rod.

The embossed portion of the wrapper may surround one or more segments of the aerosol-generating article around only a portion of the circumference of the rod. The embossed portion of the wrapper may surround one or more segments of the aerosol-generating article around no more than 80 percent of the circumference of the rod. The embossed portion of the wrapper may surround one or more segments of the aerosol-generating article around at least 20 percent of the circumference of the rod.

The embossed portion of the wrapper may surround the aerosol-generating substrate rod along at least 80 percent of the length of the rod. Preferably, the embossed portion of the wrapper surrounds the aerosol-generating substrate rod along at least 90 percent of the length of the rod. More preferably, the embossed portion of the wrapper surrounds the aerosol-generating substrate rod along 100 percent of the length of the rod.

The embossed portion of the wrapper may extend along the entire length of the wrapper. The embossed portion of the wrapper may extend only along a portion of the wrapper. In cases where the embossed portion extends only along a portion of the wrapper, the embossed portion may extend along no more than 80 percent of the length of the wrapper. In cases where the embossed portion extends only along a portion of the wrapper, the embossed portion may extend along at least 20 percent of the length of the wrapper.

The embossed portion of the wrapper may have a convex outer surface and a concave inner surface. The convex outer surface may be characterized by one or more convexities that project and are spaced from the plane of the wrapper. In this way, the surface area of the embossed portion of the wrapper that contacts the rod of the aerosol-generating substrate is reduced. This may help provide increased resistance to one or both of moisture and heat coming from the aerosol-generating substrate. The concave inner surface may be characterized by one or more concavities that correspond to an area or areas on which the wrapper has not been embossed. These concavities are in the same plane as the wrapper. The concavities on the inner surface may be in direct or indirect contact with one or more segments of the aerosol-generating article. The plane of the wrapper is obtained when the wrapper is in the unfolded state.

The embossed portion of the wrapper may have a basis weight that is greater than that of conventional wrappers for aerosol-generating articles, which are widely known in the art. A thicker wrapper may slow down or reduce the transmission of one or both of moisture and heat through the wrapper. This may help maintain the structural integrity of the aerosol-generating article and further enhance the resistance of the wrapper to one or both of moisture and heat from the aerosol-generating substrate rod. The embossed portion of the wrapper may have a basis weight of 50 grams per square meter to 100 grams per square meter. Preferably, the embossed portion of the wrapper has a basis weight of 60 grams per square meter to 90 grams per square meter. More preferably, the embossed portion of the wrapper has a basis weight of 75 grams per square meter to 80 grams per square meter.

The embossed portion of the wrapper may have multiple raised areas.

If the embossed portion of the wrapper has a plurality of convexities, each convexity may have a depth of 0.07 millimeters to 0.21 millimeters, preferably 0.10 millimeters to 0.18 millimeters, and more preferably 0.12 millimeters to 0.16 millimeters. Each convexity may also have a pitch of 0.2 millimeters to 0.4 millimeters, preferably 0.25 millimeters to 0.35 millimeters, more preferably 0.275 millimeters to 0.325 millimeters.

The embossments may be in the form of spherical domes. If each embossment is a spherical dome, the angle between the tangent to the spherical dome and the intersection with the horizontal wrap line may be between 30 degrees and 60 degrees. A plurality of embossments may be spaced apart in a repeating pattern. This repeating pattern of spaced embossments of substantially uniform depth, pitch and profile may help to provide uniform water and heat resistance properties along the surface of the embossed portion of the wrap.

The embossed portion of the wrapper may have a bending moment of 3 centinewton centimeters to 8 centinewton centimeters at 90 degrees. Preferably, the embossed portion of the wrapper has a bending moment of 4 centinewton centimeters to 7 centinewton centimeters at 90 degrees. More preferably, the embossed portion of the wrapper has a bending moment of 4 centinewton centimeters to 6 centinewton centimeters at 90 degrees.

The embossed portion of the wrapper may have an angle memory of 10 degrees to 40 degrees after bending by 90 degrees. Preferably, the embossed portion of the wrapper has an angle memory of 15 degrees to 35 degrees after bending by 90 degrees. More preferably, the embossed portion of the wrapper has an angle memory of 20 degrees to 30 degrees after bending by 90 degrees.

The bending moment and the tilt angle memory of the wrapper are measured in accordance with the bending stiffness test according to the Schlenker method in accordance with DIN 53864 (August 1978) using a suitable bending strength testing apparatus, such as that supplied by Frank Prufgerate Gmbh. The bending moment in terms of this DIN 53864 standard is the torsional moment required to bend the test specimen (paper material) by a certain angle (90 degrees) with a certain clamp length (20 millimetres). The tilt angle memory in terms of this DIN 53864 standard is the remaining angle of the test specimen after the bending moment test. A large angle means that the specimen has good crease-resistant fold properties.

The bending and twisting properties defined above may be similar to those of a conventional wrapper. By having an embossed portion of the wrapper with the bending and twisting properties defined above, it may be possible to wrap one or both of a thicker wrapper and a wrapper with a higher basis weight around a rod of aerosol-generating substrate, while maintaining the ability to manufacture an aerosol-generating article at a high speed.

The wrapper may include a layer of adhesive on the inside surface of the wrapper. Suitable adhesives are known in the art and include, but are not limited to, polyvinyl acetate (PVA) and ethylene vinyl acetate (EVA).

In prior art aerosol generating articles, the adhesive for the paper wrapper is typically provided in the form of a single longitudinal strip. When the paper wrapper is wrapped around one or more segments of the aerosol generating article, the strip of adhesive is positioned to be between the overlapping edges of the wrapper. This creates a longitudinal seam that helps hold the wrapper in the folded state. The remainder of the inner surface of the wrapper remains substantially free of adhesive.

In contrast to such conventional aerosol-generating articles, the present description provides aerosol-generating articles having an adhesive layer covering at least 50 percent of the area of the inner surface of the paper wrapper. The adhesive layer may cover at least 70 percent of the area of the inner surface of the wrapper. The adhesive layer may cover at least 90 percent of the area of the inner surface of the wrapper. The adhesive layer may cover substantially the entire area of the inner surface of the wrapper.

The inventors of the present invention have found that such an increased amount of adhesive provides several advantages over traditional adhesive compositions, in particular when used on paper wrappers with a high basis weight. In addition, it has also been found that such an increased adhesive coating does not adversely affect the reliability of the production of such aerosol-generating articles under high-speed production conditions. In particular, despite the significant increase in the adhesive coating of the wrapper, it has unexpectedly been found that there is no corresponding significant increase in one or both of the following factors: the risk of contamination of the machines with adhesive and the need for cleaning the machines. On the contrary, it has been found that, in particular for wrappers with a high basis weight, an increase in the adhesive coating can actually reduce the likelihood of jamming of the production machine due to a defect created by the wrapper. This is at least in part due to the fact that the increased adhesive coating can help to better hold the wrapper in the wrapped state and prevent one or more parts of the wrapper from opening or deviating from their wrapped position. Indeed, it has actually been found that such an increase in adhesive coverage reduces the likelihood of detecting detectable defects in the wrapper after assembly of the aerosol generating product, particularly in the case of wrappers with a high basis weight.

The adhesive layer may help secure the wrapper in place when it is wrapped around at least a portion of the aerosol-generating article. The adhesive layer may advantageously help provide a smoother appearance to the wrapper when the wrapper is wrapped around at least a portion of the aerosol-generating article. It may also provide a more aesthetically pleasing wrapper. The adhesive layer may cover at least 50 percent of the area of the inner surface of the wrapper. The adhesive layer may cover at least 70 percent of the area of the inner surface of the wrapper. The adhesive layer may cover at least 90 percent of the area of the inner surface of the wrapper. When the wrapper is wrapped around at least a portion of the aerosol-generating article, the adhesive layer on the inner surface of the wrapper may surround only one portion or component of the aerosol-generating article. Preferably, when the wrapper is wrapped around at least a portion of the aerosol-generating article, the adhesive layer on the inner surface of the wrapper may surround a plurality of parts or components of the aerosol-generating article. The adhesive layer may also help to hold one or more components of the aerosol-generating article in place. Adding the adhesive layer to the wrapper may help to more effectively hold one or more components of the aerosol-generating article by the wrapper and to minimize or eliminate any relative movement between the components.

Preferably, the adhesive layer on the inner surface of the wrapper does not extend to the edges of the inner surface of the wrapper. In such a configuration, the wrapper may have a corresponding adhesive-free region adjacent to each edge of the wrapper. The corresponding adhesive-free region adjacent to each edge of the wrapper preferably extends along the entire length of the corresponding edges of the wrapper. Alternatively, the adhesive-free areas may extend only along a portion of the edges of the wrapper corresponding to them.

In some embodiments, the adhesive layer may extend to the edges of the inner surface of the wrapper. In some embodiments, the adhesive layer may extend to one or more edges of the wrapper, but not extend to one or more other edges of the wrapper. In one example of an embodiment, the adhesive layer extends to the longitudinal edges of the wrapper, perpendicular to the direction of twisting of the wrapper, but not to the near or far edges of the wrapper.

In preferred embodiments, the adhesive layer may be on the inner surface of at least the embossed portion of the wrapper. The adhesive layer may be on the inner surface of the embossed portion of the wrapper only. The adhesive layer may be on the inner surface of the embossed portion of the wrapper, as well as on the inner surface of one or more other portions of the wrapper.

The adhesive layer may be on a portion of the inner surface of the wrapper that surrounds the aerosol-generating substrate rod. That is, at least a portion of the paper wrapper may surround the aerosol-generating substrate rod, and the adhesive layer may cover at least a portion of the inner surface of the paper wrapper surrounding the aerosol-generating substrate rod. Preferably, the adhesive layer covers the entire inner surface of the paper wrapper surrounding the aerosol-generating substrate rod. The adhesive layer may surround the aerosol-generating substrate rod along the entire circumference of the rod.

The adhesive layer may consist of one solid part. The adhesive layer may comprise a plurality of individual adhesive parts separated by adhesive-free parts of the inner surface of the wrapper. The individual adhesive parts may be randomly distributed over the inner surface of the wrapper. The individual adhesive parts may be distributed according to a pattern on the wrapper. The pattern may be a spaced, repeating pattern.

The adhesive layer may have a substantially constant thickness on the inner surface of the wrapper. The adhesive layer may be considered to have a substantially constant thickness if, when measured anywhere along the adhesive layer, the thickness is within 10 percent of the average thickness of the adhesive layer. Alternatively, the adhesive layer may have a variable thickness on the inner surface of the wrapper. When the adhesive layer comprises a plurality of adhesive parts, the plurality of adhesive parts may have different adhesive thicknesses. The adhesive layer may have different thicknesses depending on the parts or components of the aerosol-generating article that it surrounds. In embodiments in which the adhesive layer extends to at least one edge of the wrapper, the adhesive layer may have a different thickness at or near the edge of the wrapper. The adhesive layer may have a greater thickness at the edge of the wrapper. For example, in some embodiments, the adhesive layer may have a greater thickness at or near the longitudinal edges of the wrapper. The longitudinal edges of the wrapper may be more prone to detachment from the aerosol-generating article, since they are perpendicular to the direction of twisting of the wrapper. Therefore, in such example embodiments, an increased thickness of the adhesive layer at or near the longitudinal edges of the wrapper may be particularly advantageous for improving the adhesion of the longitudinal edges of the wrapper when the wrapper is wrapped around at least a portion of the aerosol-generating substrate.

If the wrapper has an embossing, the thickness of the adhesive layer may be different for each embossing of the wrapper. In particular, the thickness of the adhesive layer may be greater in each embossing of the wrapper compared to the thickness of the adhesive layer on the concavities of the wrapper. More specifically, each embossing may form a pocket into which a thicker layer of adhesive may be applied. Embosses may further help to ensure better adhesion between two or more overlapping portions of the wrapper. For example, embossing of the wrapper may increase the surface area of contact between two or more overlapping portions to improve adhesion. In addition, embossments of overlapping portions of the wrapper may be intertwined with each other to ensure better adhesion of the overlapping portions.

The adhesive layer on the inner surface of the wrapper may have a mass of more than 2.5 milligrams. The adhesive layer may have a mass of at least 5 milligrams. The adhesive layer may have a mass of at least 7.5 milligrams. The adhesive layer may have a mass of at least 10 milligrams. The adhesive layer may have a mass of at least 15 milligrams. The adhesive layer may have a mass of less than or equal to 60 milligrams. The adhesive layer may have a mass of less than or equal to 45 milligrams. The adhesive layer may have a mass of less than or equal to 30 milligrams. Preferably, the adhesive layer has a mass of 7.5 milligrams to 45 milligrams. Even more preferably, the adhesive layer may have a mass of 10 milligrams to 30 milligrams.

The aerosol-generating article according to the present invention may comprise a rod of an aerosol-generating substrate. The rod of an aerosol-generating substrate may comprise a gel composition. The gel composition may comprise at least one gelling agent, at least one of an alkaloid compound and a cannabinoid compound, and an aerosol-forming substance. The rod of an aerosol-generating substrate may have an aerosol-forming substance content of at least 5 percent based on dry weight. The aerosol-generating substrate may comprise a gel composition that includes nicotine.

The aerosol-generating substrate rod may comprise one or more aerosol forming agents. Upon evaporation, the aerosol forming agent may carry other vaporizable compounds released from the aerosol-generating substrate rod upon heating, such as nicotine and flavoring agents, into the aerosol. Suitable aerosol forming agents for inclusion in the aerosol-generating substrate rod 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 rod of the aerosol-generating substrate may have an aerosol-forming substance content of at least 10 percent on a dry weight basis. The rod of the aerosol-generating substrate may have an aerosol-forming substance content of at least 15 percent on a dry weight basis. The rod of the aerosol-generating substrate may have an aerosol-forming substance content of at least 20 percent on a dry weight basis. The rod of the aerosol-generating substrate may have an aerosol-forming substance content of at least 30 percent on a dry weight basis. The rod of the aerosol-generating substrate may have an aerosol-forming substance content of at least 40 percent on a dry weight basis. The rod of the aerosol-generating substrate may have an aerosol-forming substance content of at least 50 percent on a dry weight basis. The aerosol-generating substrate rod may have an aerosol-forming substance content of at least 60 percent on a dry weight basis. The aerosol-generating substrate rod may have an aerosol-forming substance content of at least 70 percent on a dry weight basis. The aerosol-generating substrate rod may have an aerosol-forming substance content of at least 80 percent on a dry weight basis. The aerosol-generating substrate rod may have an aerosol-forming substance content of at least 90 percent on a dry weight basis.

The aerosol generating substrate rod may have an aerosol forming substance content of from about 5 percent to about 30 percent on a dry weight basis, such as from about 10 percent to about 25 percent on a dry weight basis or from about 15 percent to about 20 percent on a dry weight basis.

For example, if the substrate is intended for use in an aerosol-generating article for an electrical aerosol-generating system having a heating element, it may preferably comprise an aerosol-forming substance content of from about 5 percent to about 30 percent, based on dry weight. If the substrate is intended for use in an aerosol-generating article for an electrical aerosol-generating system having a heating element, the aerosol-forming substance is preferably glycerol.

The rod of aerosol-generating substrate may have an aerosol forming agent content of from about 1 percent to about 5 percent on a dry weight basis. For example, if the substrate is intended for use in an aerosol-generating article in which the aerosol forming agent is retained in a reservoir separate from the substrate, the substrate may have an aerosol forming agent content of greater than 1 percent and less than about 5 percent. In such embodiments, the aerosol forming agent is vaporized upon heating, and a stream of the aerosol forming agent contacts the aerosol-generating substrate to capture flavoring substances from the aerosol-generating substrate in the aerosol.

The aerosol-generating substrate may have an aerosol former content of from about 30 percent to about 45 percent on a dry weight basis. This relatively high level of aerosol former is particularly suitable for aerosol-generating substrates that are intended to be heated at a temperature of less than 275 degrees Celsius. In such embodiments, the aerosol-generating substrate preferably further comprises from about 2 to about 10 percent on a dry weight basis of a cellulose ether and from about 5 percent to about 50 percent on a dry weight basis of additional cellulose. It has been found that the use of a combination of a cellulose ether and additional cellulose provides particularly effective aerosol delivery when used in an aerosol-generating substrate having an aerosol former content of from 30 percent to 45 percent on a dry weight basis.

Preferably, the gel composition comprises an alkaloid compound or a cannabinoid compound, or both an alkaloid compound and a cannabinoid compound; an aerosol forming agent; and at least one gelling agent. Preferably, the at least one gelling agent forms a solid medium, and glycerol is distributed in the solid medium, wherein the alkaloid or cannabinoid is distributed in the glycerol. Preferably, the gel composition is a stable gel phase.

Advantageously, a stable gel composition containing nicotine provides a predictable shape of the composition during storage or transportation from production to the consumer. A stable gel composition containing nicotine essentially maintains its shape. A stable gel composition containing nicotine essentially does not release a liquid phase during storage or transportation from production to the consumer. A stable gel composition containing nicotine can provide a simple consumable design. This consumable material can be designed without liquid content, thus a wider range of container materials and designs can be envisaged.

The gel composition described herein may be combined with an aerosol generating device to deliver a nicotine aerosol to the lungs at inhalation or air flow rates that are within the inhalation or air flow rates of a typical smoking regimen. The aerosol generating device may continuously heat the gel composition. The user may take multiple inhalations or "puffs," where each "puff" delivers a certain amount of nicotine aerosol. The gel composition may be capable of delivering a high nicotine/low total particulate matter (TPM) aerosol to the user upon heating, preferably in a continuous manner.

The phrase "stable gel phase" or "stable gel" refers to a gel that substantially maintains its shape and mass when exposed to various environmental conditions. A stable gel may not substantially release (release moisture) or absorb water when exposed to standard temperature and pressure when the relative humidity changes from about 10 percent to about 60 percent. For example, a stable gel may substantially maintain its shape and mass when exposed to standard temperature and pressure when the relative humidity changes from about 10 percent to about 60 percent.

The gel composition comprises an alkaloid compound or a cannabinoid compound, or both an alkaloid compound and a cannabinoid compound. The gel composition may contain one or more alkaloids. The gel composition may contain one or more cannabinoids. The gel composition may contain a combination of one or more alkaloids and one or more cannabinoids.

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 and fungal species. As used herein, the term "alkaloid compound" refers to both naturally occurring alkaloid compounds and synthetically produced alkaloid compounds.

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

Preferably, the gel composition contains nicotine.

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

The term "cannabinoid compound" refers to any of a class of naturally occurring compounds found in parts of the cannabis plant, namely the species Cannabis sativa, Cannabis indica, and Cannabis ruderalis. Cannabinoid compounds are particularly concentrated in the female flower heads. Cannabinoid compounds naturally occurring in the cannabis plant include cannabidiol (CBD) and tetrahydrocannabinol (THC). As used herein, the term "cannabinoid compounds" is used to describe both naturally occurring cannabinoid compounds and synthetically produced cannabinoid compounds.

The gel may comprise a cannabinoid compound selected from the group consisting of cannabidiol (CBD), tetrahydrocannabinol (THC), tetrahydrocannabinolic acid (THCA), cannabidiolic acid (CBDA), cannabinol (CBN), cannabigerol (CBG), cannabichromene (CBC), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM), cannabielsoin (CBE), cannabicitran (CBT), and combinations thereof.

The gel composition preferably comprises a cannabinoid compound selected from the group consisting of cannabidiol (CBD), THC (tetrahydrocannabinol), and combinations thereof.

The gel preferably contains cannabidiol (CBD).

The gel composition may contain nicotine and cannabidiol (CBD).

The gel composition may contain nicotine, cannabidiol (CBD) and THC (tetrahydrocannabinol).

The gel composition further comprises an aerosol forming agent. Ideally, the aerosol forming agent is substantially resistant to thermal decomposition at the operating temperature of the associated aerosol generating device. Suitable aerosol forming agents 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 forming agent is preferably glycerol.

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

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

The gel composition additionally contains at least one gelling agent.

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

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

Preferably, the gel composition comprises at least about 0.2 percent by weight of a gelling agent that provides crosslinking through hydrogen bonds. Alternatively or in addition, the gel composition preferably comprises at least about 0.2 percent by weight of a gelling agent that provides crosslinking through ionic bonds. Most preferably, the gel composition comprises at least about 0.2 percent by weight of a gelling agent that provides crosslinking through hydrogen bonds and at least about 0.2 percent by weight of a gelling agent that provides crosslinking through ionic bonds. The gel composition 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 composition in substantially equal amounts by weight.

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

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

The gel composition preferably comprises a gelling agent that provides cross-linking through hydrogen bonds in a range of from about 0.3 percent by weight to about 5 percent by weight.

The gel composition may contain galactomannan in a range of from about 0.2 percent by weight to about 5 percent by weight.

The gel composition may contain gelatin in a range of from about 0.2 percent by weight to about 5 percent by weight.

The gel composition may contain agarose in a range of from about 0.2 percent by weight to about 5 percent by weight.

The gel composition may contain konjac gum in a range of from about 0.2 percent by weight to about 5 percent by weight.

The gel composition may contain agar in a range of from about 0.2 percent by weight to about 5 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 multivalent 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 preferably comprises low acyl gellan.

The gel composition may contain a gelling agent that provides crosslinking through ionic bonds in a range of from about 0.3 percent by weight to about 5 percent by weight.

The gel composition may contain low acyl gellan in a range of from about 0.2 percent by weight to about 5 percent by weight.

The gel composition may contain pectin in a range of from about 0.2 percent by weight to about 5 percent by weight.

The gel composition may contain kappa carrageenan in a range of from about 0.2 percent by weight to about 5 percent by weight.

The gel composition may contain iota carrageenan in a range of from about 0.2 percent by weight to about 5 percent by weight.

The gel composition may contain alginate in a range of from about 0.2 percent by weight to about 5 percent by weight.

The gel composition may comprise a gelling agent that provides crosslinking through hydrogen bonds and a gelling agent that provides crosslinking through ionic bonds in a ratio of from about 3:1 to about 1:3.

The gel composition 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 added uniformly 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 viscosity without causing gel formation, but the mixture remains or remains fluid.

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

The gel composition preferably contains a viscosity increasing agent in the range of from about 0.2 percent by weight to about 5 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 composition may contain xanthan gum in a range of from about 0.2 percent by weight to about 5 percent by weight.

The gel composition may contain carboxymethylcellulose in a range of from about 0.2 percent by weight to about 5 percent by weight.

The gel composition may contain microcrystalline cellulose in a range of from about 0.2 percent by weight to about 5 percent by weight.

The gel composition may contain methylcellulose in a range of from about 0.2 percent by weight to about 5 percent by weight.

The gel composition may contain gum arabic in a range of from about 0.2 percent by weight to about 5 percent by weight.

The gel composition may contain guar gum in a range of from about 0.2 percent by weight to about 5 percent by weight.

The gel composition may contain lambda carrageenan in a range of from about 0.2 percent by weight to about 5 percent by weight.

The gel composition may contain starch in a range of from about 0.2 percent by weight to about 5 percent by weight.

The gel composition 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 composition may further comprise an acid. The acid may comprise a carboxylic acid. The carboxylic acid may comprise a ketone group. Preferably, the carboxylic acid comprises 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 (for example, lactic acid). Lactic acid unexpectedly improves the stability of the gel composition even compared to similar carboxylic acids. The carboxylic acid may promote gelation. The carboxylic acid may reduce the change in the concentration of the alkaloid compound, or the concentration of the cannabinoid compound, or the concentration of both the alkaloid compound and the cannabinoid compound within the gel composition during storage. The carboxylic acid may reduce the change in the concentration of nicotine within the gel composition during storage.

The gel composition may contain a carboxylic acid in a range of from about 0.1 percent by weight to about 5 percent by weight.

The gel composition may contain lactic acid in a range of from about 0.1 percent by weight to about 5 percent by weight.

The gel composition may contain levulinic acid in a range of from about 0.1 percent by weight to about 5 percent by weight.

The gel composition preferably contains some water. The gel composition is more stable if the composition contains some water. Preferably, the gel composition 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 composition contains at least about 10 percent by weight, or at least about 15 percent by weight of water.

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

Preferably, the aerosol generating substrate comprises from about 150 mg to about 350 mg of the gel composition.

Preferably, the aerosol generating substrate comprises a porous medium filled with a gel composition. The advantages of a porous medium filled with a gel composition are that the gel composition is retained within the porous medium, and this can facilitate the manufacture, storage or transportation of the gel composition. This can help maintain the desired shape of the gel composition, especially during manufacture, transportation or use.

The term "porous" is used in this document to refer to a material that provides multiple pores or openings that allow air to pass through the material.

The porous medium may be any suitable porous material capable of holding or retaining the gel composition. Ideally, the porous medium may allow the gel composition to move within it. The porous medium may comprise natural materials, synthetic or semi-synthetic materials, or a combination thereof. The porous medium may comprise a sheet material, a foam material, or fibers, such as loose fibers, or a combination thereof. The porous medium may comprise a woven, non-woven or extruded material, or combinations thereof. Preferably, the porous medium comprises cotton, paper, viscose, PLA or cellulose acetate, or combinations thereof. Preferably, the porous medium comprises a sheet material, such as cotton or cellulose acetate. Preferably, the porous medium may comprise a sheet made of cotton fibers.

The porous medium may be corrugated or split. Preferably, the porous medium is corrugated. Alternatively, the porous medium provides a split porous medium. The corrugation or splitting process may occur before or after filling with the gel composition.

Corrugation of the sheet material has the advantage of improving the structure to provide passages through the structure. The passages through the corrugated sheet material assist in filling the gel, retaining the gel, and also for the fluid to pass through the corrugated sheet material. Therefore, there are advantages to using the corrugated sheet material as a porous medium.

The splitting provides a high surface area to volume ratio for the medium, which is thus able to easily absorb the gel.

The sheet material may be a composite material. Preferably, the sheet material is porous. The sheet material may facilitate the production of a tubular element containing a gel. The sheet material may facilitate the introduction of an active substance into the tubular element containing a gel. The sheet material may facilitate the stabilization of the structure of the tubular element containing a gel. The sheet material may facilitate the transportation or storage of the gel. The use of the sheet material allows or provides the addition of structure to a porous medium, for example by corrugating the sheet material.

The porous medium may be a thread. The thread may contain, for example, cotton, paper or acetate rod. The thread may also be filled with a gel, like any other porous medium. The advantage of using a thread as a porous medium is that it can facilitate easy fabrication.

The thread may be filled with gel by any known means. The thread may simply be coated with gel, or the thread may be impregnated with gel. The threads may be impregnated with gel during manufacture and stored ready for use for incorporation into a tubular assembly.

The porous medium filled with the gel composition is preferably provided inside a tubular element that forms part of the aerosol-generating article. Ideally, the tubular element may be longer in longitudinal length than in width, but not necessarily, since it may be one part of a multi-component element that will ideally be longer in its longitudinal length than in its width. Typically, the tubular element is cylindrical, but not necessarily. For example, the tubular element may have an oval, polygonal, such as triangular or rectangular, or arbitrary cross-section.

The tubular element preferably comprises a first longitudinal passage. The tubular element is preferably formed from a wrapper that defines the first longitudinal passage. The wrapper is preferably a water-resistant wrapper. This water-resistant property of the wrapper can be achieved by using a water-resistant material or by treating the wrapper material. This can be achieved by treating one side or both sides of the wrapper. The presence of water resistance will help to prevent loss of structure, rigidity or strength. It can also help to prevent leakage of the gel or liquid, especially when using gels of a flowable structure.

The aerosol generating article may be provided with an upstream element that is upstream of the aerosol generating substrate rod. The upstream element may be adjacent to the upstream end of the aerosol generating substrate rod.

The aerosol generating article may be provided with a downstream section located downstream of the aerosol generating substrate rod and in axial alignment with the aerosol generating substrate rod. The downstream section may comprise one or more downstream elements.

The aerosol generating substrate may be heated by means of an internal heating plate in an electrically heated aerosol generating device adapted to be inserted into the aerosol generating substrate. The aerosol generating substrate may be inductively heated by means of a current collecting (=susceptor) element located within the aerosol generating substrate.

Providing an upstream element can advantageously protect the aerosol-generating substrate rod and prevent physical contact with the gel composition inside the aerosol-generating substrate rod and the current-collecting element, if present. The upstream element can be an adjacent portion relative to the aerosol-generating substrate rod, which can also be surrounded by an embossed portion of the wrapper.

The downstream section may comprise a mouthpiece element. The mouthpiece element may extend the entire distance to the mouthpiece end of the aerosol-generating article. The mouthpiece element may be an adjacent portion relative to the aerosol-generating substrate rod, which may also be surrounded by an embossed portion of the wrapper. The downstream section may further comprise an intermediate hollow section between the mouthpiece element and the aerosol-generating substrate rod. The intermediate hollow section may comprise an aerosol-cooling element. The aerosol-cooling element may comprise a hollow tubular segment. The intermediate hollow section may comprise a support element, which may comprise a hollow tubular segment. The intermediate hollow section may comprise an aerosol-cooling element and a support element. The support element may be located earlier along the flow path relative to the aerosol-cooling element. The intermediate hollow section may be an adjacent portion relative to the aerosol generating substrate rod, which may also be surrounded by an embossed portion of the wrapper.

In the context of this document, the term "hollow tubular element" is 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 a tubular element that has a substantially cylindrical cross-section and defines at least one air duct that establishes continuous fluid communication between an upstream end of the tubular element and a downstream end of the tubular element. However, it should be understood that alternative geometric parameters (e.g., alternative cross-sectional shapes) of the tubular segment may be possible.

In the context of this document, the term "elongated" means that the element has a length dimension that is greater than its width dimension or its diameter dimension, such as twice or greater than its width dimension or its diameter dimension.

In the context of the present invention, the hollow tubular segment provides an unobstructed flow channel. This means that the hollow tubular segment provides a low level of resistance to draw (RTD). Therefore, the flow channel must be free of any components that can restrict the air flow in the longitudinal direction. Preferably, the flow channel is substantially empty.

The aerosol generating article may comprise a ventilation zone at a location along a downstream section. In more detail, the aerosol generating article may comprise a ventilation zone at a location along an aerosol cooling element. The aerosol cooling element may be in the form of a hollow tubular segment or comprise it, wherein the ventilation zone is provided at a location along the hollow tubular segment of the aerosol cooling element.

It has been found that satisfactory cooling of the aerosol flow generated by heating the aerosol generating substrate and drawn through one such aerosol cooling element is achieved by providing a ventilation zone at a location along the hollow tubular segment. It has also been found that, as will be described in more detail below, by arranging the ventilation zone at a precisely determined location along the length of the aerosol cooling element and by preferably using a hollow tubular segment having a predetermined peripheral wall thickness or internal volume, it may be possible to counteract the effects of increased aerosol dilution caused by the admission of ventilation air into the article.

The rod of the aerosol-generating substrate may further comprise a current-collecting element. The current-collecting element may be an elongated current-collecting element. Preferably, the current-collecting element extends in the longitudinal direction inside the aerosol-generating substrate.

These elements of the aerosol generating product will be described in more detail below.

As defined above, the aerosol generating article according to the present invention comprises a rod of aerosol generating substrate. The aerosol generating substrate may be a solid aerosol generating substrate.

The elongated current collecting element can be arranged substantially in a longitudinal direction within the rod of the aerosol generating substrate and can be in thermal contact with the aerosol generating substrate.

In the context of this document with reference to the present invention, the term "susceptor element" refers to a material that can convert electromagnetic energy into heat. When placed inside a fluctuating electromagnetic field, eddy currents induced in the susceptor element cause the susceptor element to heat up. Since the elongated susceptor element is placed in thermal contact with the aerosol-generating substrate, the aerosol-generating substrate is heated by the susceptor element.

When used to describe a current collecting element, the term "elongated" means that the current collecting element has a length dimension that is greater than its width dimension or its thickness dimension, for example, twice its width dimension or its thickness dimension.

The current collecting element is arranged substantially longitudinally within the rod. This means that the length dimension of the elongated current collecting element is arranged approximately parallel to the longitudinal direction of the rod, for example, in the range of plus or minus 10 degrees parallel to the longitudinal direction of the rod. The elongated current collecting element may be arranged in a radial central position within the rod and extends along the longitudinal axis of the rod.

Preferably, the current collecting element extends the entire distance to the downstream end of the rod of the aerosol-generating article. The current collecting element may extend the entire distance to the upstream end of the rod of the aerosol-generating article. The current collecting element may have substantially the same length as the rod of the aerosol-generating substrate and extend from the upstream end of the rod to the downstream end of the rod.

The current collecting element may preferably be in the form of a pin, rod, strip or plate.

The current collecting element may preferably have a length of from about 5 millimeters to about 15 millimeters, such as from about 6 millimeters to about 12 millimeters or from about 8 millimeters to about 10 millimeters.

The ratio between the length of the current collecting element and the total length of the substrate of the aerosol generating article may be from about 0.2 to about 0.35.

Preferably, the ratio between the length of the current collecting element and the total length of the substrate of the aerosol generating article is at least about 0.22, more preferably at least about 0.24, even more preferably at least about 0.26. The ratio between the length of the current collecting element and the total length of the substrate of the aerosol generating article is preferably less than about 0.34, more preferably less than about 0.32, even more preferably less than about 0.3.

The ratio between the length of the current collecting element and the total length of the substrate of the aerosol generating article is preferably from about 0.22 to about 0.34, more preferably from about 0.24 to about 0.34, even more preferably from about 0.26 to about 0.34. The ratio between the length of the current collecting element and the total length of the substrate of the aerosol generating article is preferably from about 0.22 to about 0.32, more preferably from about 0.24 to about 0.32, even more preferably from about 0.26 to about 0.32. The ratio between the length of the current collecting element and the total length of the substrate of the aerosol generating article is preferably from about 0.22 to about 0.3, more preferably from about 0.24 to about 0.3, even more preferably from about 0.26 to about 0.3.

The ratio between the length of the current collecting element and the total length of the substrate of the aerosol generating article may be approximately 0.27.

The current collecting element preferably has a width of from approximately 1 millimeter to approximately 5 millimeters.

The current collecting element may typically have a thickness of about 0.01 millimeters to about 2 millimeters, such as about 0.5 millimeters to about 2 millimeters. The current collecting element preferably has a thickness of about 10 micrometers to about 500 micrometers, more preferably about 10 micrometers to about 100 micrometers.

If the current collecting element has a constant cross-section, for example a circular cross-section, it has a preferred width or diameter of from approximately 1 millimeter to approximately 5 millimeters.

If the current collecting element has the form of a strip or plate, the strip or plate preferably has a rectangular shape with a width of preferably from about 2 millimeters to about 8 millimeters, more preferably from about 3 millimeters to about 5 millimeters. As an example, the current collecting element in the form of a strip of plate can have a width of about 4 millimeters.

If the current collecting element has the form of a strip or plate, the strip or plate preferably has a rectangular shape and a thickness of about 0.03 millimeters to about 0.15 millimeters, more preferably from about 0.05 millimeters to about 0.09 millimeters. As an example, the current collecting element in the form of a strip or plate may have a thickness of about 0.07 millimeters.

The elongated current collecting element may be in the form of a strip or plate, preferably has a rectangular shape and has a thickness of from about 55 micrometers to about 65 micrometers.

More preferably, the elongated current collecting element may have a thickness of about 57 micrometers to about 63 micrometers. Even more preferably, the elongated current collecting element has a thickness of about 58 micrometers to about 62 micrometers. The elongated current collecting element may have a thickness of about 60 micrometers.

Preferably, the elongated current-collecting element may have a length that is equal to or shorter than the length of the aerosol-generating substrate. Preferably, the elongated current-collecting element has the same length as the aerosol-generating substrate.

The current collecting element may be formed from any material that can be inductively heated to a temperature sufficient to generate an aerosol from an aerosol generating substrate. Preferred current collecting elements comprise metal or carbon.

A preferred current collector may comprise or consist of a ferromagnetic material, such as a ferromagnetic alloy, ferritic iron, or ferromagnetic steel, or stainless steel. A suitable current collector may be made of or comprise aluminum. Preferred current collectors may be formed from 400 series stainless steels, such as 410 series stainless steel, or 420 series stainless steel, or 430 series stainless steel. Different materials will dissipate different amounts of energy when they are located within electromagnetic fields having similar frequency and field strength values.

Thus, all parameters of the current collecting element, such as the type of material, length, width and thickness, can be changed to provide the desired power dissipation within a known electromagnetic field. Preferred current collecting elements can be heated to temperatures in excess of 250 degrees Celsius.

Suitable current-collecting elements may comprise a non-metallic core with a metal layer located on the non-metallic core, for example with metal tracks formed on the surface of a ceramic core. The current-collecting element may have a protective outer layer, for example a protective ceramic layer or a protective glass layer, covering the current-collecting element. The current-collecting element may comprise a protective coating formed from glass, ceramic or inert metal, formed over the core material of the current-collecting element.

The current-receiving element is arranged in thermal contact with the aerosol-generating substrate. Thus, when the current-receiving element is heated, the aerosol-generating substrate is heated and an aerosol is formed. Preferably, the current-receiving element is arranged in direct physical contact with the aerosol-generating substrate, for example, inside the aerosol-generating substrate.

The current collecting element may be a current collecting element consisting of several materials, and may comprise a first current collecting element material and a second current collecting element material. The first current collecting element material is located in direct physical contact with the second current collecting element material. The second current collecting element material preferably has a Curie temperature that is lower than 500 degrees Celsius. The first current collecting element material is preferably used mainly for heating the current collecting element when the current collecting element is placed in a fluctuating electromagnetic field. Any suitable material may be used. For example, the first current collecting element material may be aluminum or may be a ferrous metal, such as stainless steel. The second current collecting element material is preferably used mainly for indicating that the current collecting element has reached a specific temperature, wherein this temperature is the Curie temperature of the second current collecting element material. The Curie temperature of the second current-collecting element material can be used to control the temperature of the entire current-collecting element during operation. Thus, the Curie temperature of the second current-collecting element material should be below the ignition point of the aerosol-generating substrate. Suitable materials for the second current-collecting element material may include nickel and certain nickel alloys.

By providing a current-receiving element having at least a first and a second current-receiving element material, wherein either the second current-receiving element material has a Curie temperature and the first current-receiving element material does not have a Curie temperature, or the first and second current-receiving element materials have a first and a second Curie temperature different from each other, it is possible to separate the heating of the aerosol-generating substrate and to regulate the heating temperature. The first current-receiving element material is preferably a magnetic material having a Curie temperature that is higher than 500 degrees Celsius. From the viewpoint of heating efficiency, it is desirable that the Curie temperature of the first current-receiving element material exceeds any maximum temperature to which the current-receiving element should be able to be heated. The second Curie temperature is preferably selected such that it is lower than 400 degrees Celsius, preferably lower than 380 degrees Celsius or lower than 360 degrees Celsius. Preferably, the second material of the current-receiving element is a magnetic material selected in such a way that it has a second Curie temperature that substantially coincides with the desired maximum heating temperature. That is, it is preferable that the second Curie temperature is approximately the same as the temperature to which the current-receiving element must be heated in order to generate an aerosol from the aerosol-generating substrate. The second Curie temperature can, for example, be within the range of 200 degrees Celsius to 400 degrees Celsius or from 250 degrees Celsius to 360 degrees Celsius. The second Curie temperature of the second material of the current-receiving element can, for example, be selected such that when heated by the current-receiving element, which is at a temperature equal to the second Curie temperature, the overall average temperature of the aerosol-generating substrate does not exceed 240 degrees Celsius.

The aerosol-generating article may comprise a ventilation zone. The aerosol-generating article may have a ventilation level of at least approximately 5 percent.

The term "ventilation level" is used throughout this specification to mean the volumetric ratio between the airflow admitted into the aerosol-generating article through the ventilation zone (ventilation airflow) and the sum of the aerosol-containing airflow and the ventilation airflow. The higher the ventilation level, the greater the dilution of the aerosol flow delivered to the consumer.

The aerosol generating article may typically have a ventilation level of at least about 10 percent, preferably at least about 15 percent, more preferably at least about 20 percent.

The aerosol-generating article may have a ventilation level of at least about 25 percent. The aerosol-generating article preferably has a ventilation level of less than about 60 percent. The aerosol-generating article according to the present invention preferably has a ventilation level of about 45 percent or less. More preferably, the aerosol-generating article according to the present invention has a ventilation level of about 40 percent or less, even more preferably about 35 percent or less.

The aerosol-generating article may have a ventilation level of about 30 percent. The aerosol-generating article may have a ventilation level of about 20 percent to about 60 percent, preferably about 20 percent to about 45 percent, more preferably about 20 percent to about 40 percent. Alternatively, the aerosol-generating article may have a ventilation level of about 25 percent to about 60 percent, preferably about 25 percent to about 45 percent, more preferably about 25 percent to about 40 percent. Alternatively, the aerosol-generating article may have a ventilation level of about 30 percent to about 60 percent, preferably about 30 percent to about 45 percent, more preferably about 30 percent to about 40 percent.

An aerosol-generating product may have a ventilation level of approximately 28 percent to approximately 42 percent. An aerosol-generating product may have a ventilation level of approximately 30 percent.

The formation of an aerosol from a gaseous mixture containing various chemical compounds depends on the subtle interactions of nucleation, evaporation and condensation, and droplet coalescence, while taking into account changes in vapor concentration, temperature and velocity fields. The so-called classical nucleation theory is based on the assumption that a fraction of molecules in the gas phase is large enough to remain coherent for a long time with a sufficient probability (e.g. fifty-fifty probability). These molecules represent some kind of critical threshold molecular clusters among short-lived molecular aggregates, meaning that, in general, smaller molecular clusters in the gas phase are more likely to disintegrate quickly enough, while larger clusters are, in general, more likely to grow. Such a critical cluster is identified with the key nucleation nucleus from which droplet growth is expected due to condensation of molecules from the vapor. Primary droplets that have just formed are assumed to appear with a certain initial diameter and can then grow by several orders of magnitude. This is simplified and can be accelerated by rapid cooling of the surrounding vapor, which causes condensation. Thus, it helps to consider that evaporation and condensation are two sides of the same mechanism, namely mass transfer between a gas and a liquid. Whereas evaporation refers to a net mass transfer from the liquid droplets to the gas phase, condensation is a net mass transfer from the gas phase to the droplet phase. Evaporation (or condensation) will cause a decrease in volume (or growth) of the droplets, but will not change the number of droplets.

In this scenario, which may be further complicated by droplet coalescence phenomena, temperature and cooling rate may play an important role in determining the response of the system. In general, different cooling rates may result in significantly different time behavior with respect to liquid phase (droplet) formation, since the nucleation process is typically nonlinear. Without being limited by theory, it is suggested that cooling may cause a rapid increase in droplet number concentration, followed by a strong short-term increase in droplet growth (nucleation burst). This nucleation burst may be more significant at lower temperatures. It may also be that higher cooling rates may favor an earlier onset of nucleation. In contrast, a decrease in the cooling rate may have a beneficial effect on the final size that the aerosol droplets eventually reach.

The inventors of the present invention have surprisingly found that the effect of dilution on the aerosol, which can be assessed by measurement, in particular the effect on the delivery of the aerosol forming substance (such as glycerol) contained in the aerosol generating substrate, is advantageously minimized when the ventilation level is within the ranges described above. In particular, it has been found that ventilation levels from 25 percent to 50 percent, and even more preferably from 28 to 42 percent, lead to particularly satisfactory values of glycerol delivery. At the same time, the duration of nucleation and, therefore, the delivery of nicotine and the aerosol forming substance (such as glycerol) are improved.

The inventors of the present invention have surprisingly discovered how the beneficial effect of improved nucleation provided by rapid cooling caused by the introduction of ventilation air into the article can significantly counteract the less desirable dilution effects. Thus, satisfactory aerosol delivery values are consistently achieved by the aerosol-generating articles according to the present invention.

This is particularly advantageous for "short" aerosol-generating articles, such as articles in which the length of the aerosol-generating substrate rod is less than about 40 millimeters, preferably less than 25 millimeters, even more preferably less than 20 millimeters, or where the overall length of the aerosol-generating article is less than about 70 millimeters, preferably less than about 60 millimeters, even more preferably less than 50 millimeters. It should be understood that in such aerosol-generating articles there is little time and space for the aerosol to form and for the particulate phase of the aerosol to be available for delivery to the consumer.

The aerosol generating article according to the present invention may have a length from about 35 millimeters to about 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. Alternatively, 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. Alternatively, 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. Preferably, the overall length of the aerosol generating article is approximately 45 millimeters.

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

The diameter (D _ME ) of the aerosol-generating article at the mouth end is preferably larger than the diameter (D _DE ) of the aerosol-generating article at the distal end. In more detail, the ratio (D _ME /D _DE ) between the diameter of the aerosol-generating article at the mouth end and the diameter of the aerosol-generating article at the distal end is preferably at least approximately 1.005.

Preferably, the ratio (D _ME /D _DE ) between the diameter of the aerosol-generating article at the mouth end and the diameter of the aerosol-generating article at the distal end is at least about 1.01. More preferably, the ratio (D _ME /D _DE ) between the diameter of the aerosol-generating article at the mouth end and the diameter of the aerosol-generating article at the distal end is at least about 1.02. Even more preferably, the ratio (D _ME /D _DE ) between the diameter of the aerosol-generating article at the mouth end and the diameter of the aerosol-generating article at the distal end is at least about 1.05.

The ratio (D _ME /D _DE ) between the diameter of the aerosol-generating article at the mouth end and the diameter of the aerosol-generating article at the distal end is preferably less than or equal to about 1.30. More preferably, the ratio (D _ME /D _DE ) between the diameter of the aerosol-generating article at the mouth end and the diameter of the aerosol-generating article at the distal end is less than or equal to about 1.25. Even more preferably, the ratio (D _ME /D _DE ) between the diameter of the aerosol-generating article at the mouth end and the diameter of the aerosol-generating article at the distal end is less than or equal to about 1.20. Preferably, the ratio (D _ME /D _DE ) between the diameter of the aerosol-generating article at the mouth end and the diameter of the aerosol-generating article at the distal end is less than or equal to 1.15 or 1.10.

The ratio (D _ME /D _DE ) between the diameter of the aerosol generating article at the mouth end and the diameter of the aerosol generating article at the distal end is from about 1.01 to 1.30, more preferably from 1.02 to 1.30, even more preferably from 1.05 to 1.30.

Alternatively, the ratio (D _ME /D _DE ) between the diameter of the aerosol-generating article at the mouth end and the diameter of the aerosol-generating article at the distal end may be approximately 1.01 to 1.25, more preferably 1.02 to 1.25, even more preferably 1.05 to 1.25. Alternatively, the ratio (D _ME /D _DE ) between the diameter of the aerosol-generating article at the mouth end and the diameter of the aerosol-generating article at the distal end may be approximately 1.01 to 1.20, more preferably 1.02 to 1.20, even more preferably 1.05 to 1.20. Alternatively, the ratio (D _ME /D _DE ) between the diameter of the aerosol generating article at the mouth end and the diameter of the aerosol generating article at the distal end is approximately 1.01 to 1.15, more preferably 1.02 to 1.15, even more preferably 1.05 to 1.15.

As an example, the outer diameter of the article may be substantially constant at a distal portion of the article extending from the distal end of the aerosol-generating article by at least about 5 millimeters or at least about 10 millimeters. Alternatively, the outer diameter of the article may taper at a distal portion of the article extending from the distal end by at least about 5 millimeters or at least about 10 millimeters.

The elements of the aerosol generating article, as described above, can be arranged such that the center of mass of the aerosol generating article is at a point at least approximately 60 percent of the way along the length of the aerosol generating article relative to the downstream end. More preferably, the elements of the aerosol generating article are arranged such that the center of mass of the aerosol generating article is at a point at least approximately 62 percent of the way along the length of the aerosol generating article relative to the downstream end, more preferably at a point at least approximately 65 percent of the way along the length of the aerosol generating article relative to the downstream end.

Preferably, the center of mass is located at a point no more than approximately 70 percent of the way along the length of the aerosol generating article relative to the downstream end.

Providing an arrangement of the elements such that the center of mass is closer to the upstream end than to the downstream end may result in the aerosol generating article having a weight imbalance with the heavier upstream end. This weight imbalance may advantageously provide tactile feedback to the consumer so that they can differentiate between the upstream and downstream ends so that the correct end can be inserted into the aerosol generating device.

An aerosol-generating article according to the present invention may comprise, in a linear sequential arrangement, a plurality of segments comprising: an upstream element; a rod made of an aerosol-generating substrate located immediately downstream of the upstream element; a support element located immediately downstream of the rod made of an aerosol-generating substrate; an aerosol-cooling element located immediately downstream of the support element; a mouthpiece element located immediately downstream of the aerosol-cooling element; and an outer wrapper surrounding the upstream element, the support element, the aerosol-cooling element, and the mouthpiece element.

In more detail, the aerosol-generating substrate rod may be adjacent to an upstream element. The support element may be adjacent to the aerosol-generating substrate 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 may have a substantially cylindrical shape and an outer diameter of approximately 7.25 millimeters.

The upstream element may have a length of approximately 5 millimeters, the rod of the aerosol-generating article may have a length of approximately 12 millimeters, the support element may have a length of approximately 8 millimeters, and the mouthpiece element may have a length of approximately 12 millimeters. Thus, the total length of the aerosol-generating article may be approximately 45 millimeters.

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

An aerosol-generating article may comprise an elongated current-receiving element arranged substantially in the longitudinal direction inside a rod of aerosol-generating substrate and may be in thermal contact with the aerosol-generating substrate. The current-receiving element may be in the form of a strip or plate, may have a length substantially equal to the length of the rod of aerosol-generating substrate, and a thickness of approximately 60 micrometers.

The support member may be in the form of a hollow cellulose acetate tube and may have an internal diameter of approximately 1.9 millimeters. Thus, the thickness of the peripheral wall of the support member may be approximately 2.675 millimeters.

The aerosol cooling element may be in the form of a thinner hollow cellulose acetate tube and may have an internal diameter of approximately 3.25 millimeters. Thus, the thickness of the peripheral wall of the aerosol cooling element may be approximately 2 millimeters.

The mouthpiece element may be in the form of a low density cellulose acetate filter segment.

The aerosol generating substrate rod may comprise an aerosol generating substrate comprising a gel composition.

Features described with respect to one example or embodiment may also be applied to other examples and embodiments.

The following is a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more features of another example, embodiment, or aspect described herein.

EX1. An aerosol-generating article for producing an inhalable aerosol upon heating, wherein the aerosol-generating article comprises: optionally a rod of an aerosol-generating substrate; and a paper wrapper wrapped around at least a portion of the aerosol-generating article, wherein the paper wrapper optionally comprises an embossed portion and optionally has a basis weight of from 50 grams per square meter to 100 grams per square meter.

EX2. An aerosol-generating article according to claim 1, wherein the content of the aerosol-forming substance in the rod of the aerosol-generating substrate is at least 5 percent based on dry weight.

EX3. An aerosol generating article according to example EX1 or EX2, wherein the embossed portion of the wrapper has a basis weight of between 60 grams per square metre and 70 grams per square metre.

EX4. An aerosol generating article according to example EX1 or EX2, wherein the embossed portion of the wrapper has a basis weight of between 75 grams per square metre and 80 grams per square metre.

EX5. An aerosol generating article according to any of examples EX1-EX4, wherein at least the embossed portion of the wrapper is a water-resistant wrapper.

EX6. An aerosol-generating article according to any of examples EX1-EX5, wherein the wrapper further comprises: an inner surface; an outer surface; and a layer of adhesive on the inner surface of the wrapper; wherein the layer of adhesive covers at least 50 percent of the area of the inner surface of the wrapper.

EX7. An aerosol generating article according to example EX6, wherein the adhesive layer covers at least 70 percent of the area of the inner surface of the wrapper.

EX8. An aerosol generating article according to example EX6, wherein the adhesive layer covers at least 90 percent of the area of the inner surface of the wrapper.

EX9. An aerosol generating article according to any of EX6-EX8, wherein the adhesive layer has a substantially constant thickness over the entire inner surface of the wrapper.

EX10. An aerosol generating article according to any of examples EX6-EX9, wherein the adhesive layer on the inner surface of the wrapper has a mass of from 15 milligrams to 45 milligrams, preferably from 20 milligrams to 40 milligrams, most preferably from 25 milligrams to 35 milligrams.

EX11. An aerosol generating article according to any of examples EX6-EX10, wherein the wrapper has a first edge at a near end of the wrapper and a second edge at a far end of the wrapper.

EX12. An aerosol generating article according to any of the examples EX6-EX11, wherein the adhesive layer does not extend to the first and second edges of the inner surface of the wrapper.

EX13. An aerosol generating article according to any one of examples EX1-EX12, wherein the aerosol generating substrate rod comprises an aerosol forming substance having a glycerol content of at least about 10 percent by weight.

EX14. An aerosol-generating article according to any of EX1-EX13, wherein the embossed portion of the wrapper directly surrounds the rod of the aerosol-generating substrate.

EX15. An aerosol generating article according to any of EX1-EX14, wherein the embossed portion completely surrounds the rod of aerosol generating substrate around the circumference of the rod.

EX16. An aerosol-generating article according to any of examples EX1-EX15, wherein the embossed portion surrounds the rod of aerosol-generating substrate over at least 80 percent of the length of the rod, preferably over at least 90 percent of the length of the rod, more preferably over 100 percent of the length of the rod.

EX17. An aerosol-generating article according to any of the examples EX1-EX16, wherein the embossed portion of the wrapper has an outer surface with convexities and an inner surface with concavities.

EX18. An aerosol generating article according to any of the examples EX1-EX17, wherein the embossed portion of the wrapper has a plurality of convexities.

EX19. An aerosol generating article according to example EX18, wherein each protrusion has a depth of between 0.07 millimeters and 0.21 millimeters.

EX20. An aerosol generating article according to examples EX18 or EX19, wherein each protrusion has a pitch of from 0.2 millimetres to 0.4 millimetres.

EX21. An aerosol generating article according to any of EX18-EX19, wherein each protuberance is a spherical dome.

EX22. An aerosol generating article according to example EX21, wherein the angle between the tangent to the spherical dome and the intersection with the horizontal wrap line is between 30 degrees and 60 degrees.

EX23. An aerosol generating article according to any of EX22-EX21, wherein the plurality of protrusions are provided spaced apart in a repeating pattern.

EX24. An aerosol generating article according to any of the examples EX1-EX23, wherein the embossed portion of the wrapper has a bending moment of from 3 centinewton centimeters to 8 centinewton centimeters at 90 degrees, preferably from 4 centinewton centimeters to 7 centinewton centimeters, more preferably from 5 centinewton centimeters to 6 centinewton centimeters.

EX25. An aerosol generating article according to any of the examples EX1-EX24, wherein the embossed portion of the wrapper has an angle memory of 10 degrees to 40 degrees after bending by 90 degrees, preferably from 15 degrees to 35 degrees, more preferably from 20 degrees to 30 degrees.

EX26. An aerosol generating article according to any of the examples EX1-EX25, wherein the aerosol generating substrate rod comprises a gel composition.

EX27. An aerosol generating article according to example EX26, wherein the gel composition comprises at least one gelling agent and at least one of an alkaloid compound and a cannabinoid compound.

EX28. An aerosol generating article according to example EX27, wherein the gel composition comprises an aerosol forming substance.

EX29. An aerosol generating article according to any of the examples EX1-EX28, wherein the rod of the aerosol generating substrate comprises a plug of a porous medium filled with a gel composition.

EX30. An aerosol generating article according to example EX29, in which the porous medium is in the form of a corrugated sheet.

EX31. An aerosol generating article according to example EX29 or EX30, wherein the porous medium comprises cotton fibres.

EX32. An aerosol generating article according to any of EX29-EX31, wherein the gel composition comprises at least 1 percent by weight of nicotine.

EX33. An aerosol generating article according to any of the examples EX26-EX32, wherein the gel composition further comprises an acid.

EX34. An aerosol generating article according to any of EX26-EX33, wherein the gel composition comprises from 1 percent by weight to 6 percent by weight of at least one gelling agent.

EX35. An aerosol generating article according to any of the examples EX1-EX34, further comprising an elongated current collecting element extending longitudinally through the rod of the aerosol generating substrate.

EX36. An aerosol generating article according to any of the examples EX1-EX35, further comprising an upstream element provided upstream of the aerosol generating substrate rod and adjacent to the upstream end of the aerosol generating substrate rod.

EX37. An aerosol generating article according to any one of EX1-EX36, further comprising a downstream section located downstream of the aerosol generating substrate rod and in axial alignment with the aerosol generating substrate rod, wherein the downstream section comprises one or more downstream elements.

EX38. An aerosol generating article according to example EX36 or EX37, wherein the upstream element comprises a plug made of fibrous filter material.

EX39. An aerosol generating article according to any of EX32-EX33, wherein the upstream element has a draw resistance of at least 20 H2O.

EX40. An aerosol generating article according to any of EX37-EX39, wherein the downstream section comprises a mouthpiece element comprising a mouthpiece filter segment formed from a fibrous filter material.

EX41. An aerosol generating article according to example EX40, wherein the draw resistance of the upstream element is at least 1.5 times greater than the draw resistance of the mouthpiece element.

EX42. An aerosol generating article according to example EX40 or EX41, wherein the downstream section further comprises an intermediate hollow section between the rod of aerosol generating substrate and the mouthpiece element, wherein the intermediate hollow section comprises an aerosol cooling element adjacent to the upstream end of the mouthpiece element, and the aerosol cooling element comprises a hollow tubular segment forming a longitudinal cavity providing an unobstructed flow channel.

EX43. An aerosol generating article according to example EX42, wherein the intermediate hollow section further comprises a support element between the aerosol cooling element and the aerosol generating substrate rod, wherein the support element comprises a hollow tubular segment forming a longitudinal cavity providing an unobstructed flow channel.

EX44. A method for producing an aerosol-generating article, the method comprising: providing a rod of aerosol-generating substrate; providing a paper wrapper with a basis weight of from 50 grams per square meter to 100 grams per square meter; embossing a portion of the paper wrapper; and wrapping the wrapper around the aerosol-generating article such that the embossed portion surrounds at least the rod of aerosol-generating substrate.

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

Fig. 1 is a schematic cross-sectional side view of an aerosol generating article according to a first embodiment of the present invention;

Fig. 2 is a schematic cross-sectional side view of an aerosol generating article according to a second embodiment of the present invention;

Fig. 3 is a schematic cross-sectional side view of an aerosol generating article according to a third embodiment of the present invention;

Fig. 4 is a top view of a pattern of embossed portions of a wrapper intended for use with an aerosol generating article of an embodiment of the present invention;

Fig. 5 is a schematic cross-sectional side view of a pattern of protrusions on an embossed portion of a wrapper intended for use with an aerosol-generating article of an embodiment of the present invention;

Fig. 6 is a schematic side view in section of a double stick for forming an aerosol generating article according to an embodiment of the present invention;

Fig. 7 shows a top view of the first example of a wrapper;

Fig. 8 shows a top view of a second example of a wrapper; and

Fig. 9 is a schematic side sectional view of an aerosol generating article according to a fourth embodiment of the present invention.

Embodiments of the present invention will now be described in detail, by way of example only, with reference to the accompanying drawings, in which the following is provided.

Fig. 1 shows an aerosol-generating article 1 according to a first embodiment of the present invention. The aerosol-generating article 1 comprises a rod 111 of an aerosol-generating substrate 112 and a downstream section 114 at a location downstream of the rod 111 of an aerosol-generating substrate 112. Furthermore, the aerosol-generating article 1 comprises an upstream section 16 at a location upstream of the rod 111 of an aerosol-generating substrate 112. Thus, the aerosol-generating article 1 extends from an upstream or distal end 18 to a downstream or mouth end 20.

The aerosol generating product has an overall length of approximately 45 millimetres.

The downstream section 114 comprises a tubular element 100 arranged immediately downstream of the rod 111 of the aerosol-generating substrate 112, wherein the tubular element 100 is in longitudinal alignment with the rod 111 of the aerosol-generating substrate 112. In the embodiment of Fig. 1, the upstream end of the tubular element 100 is adjacent to the downstream end of the rod 111 of the aerosol-generating substrate 12, and in particular to the downstream end of the rod 111.

The rod 111 comprises an aerosol generating substrate 112 comprising a porous medium filled with a gel composition as defined above. An example of a suitable gel composition is shown below in Table 1:

Table 1: Gel composition

Component Quantity (% by weight) Water 20 Glycerol 73.5 Nicotine 1.5 Gelling agent 3 Lactic acid 1 Divalent cations 1

In addition, the downstream section 114 comprises a mouthpiece element 42 at a location downstream of the tubular element 100. In more detail, the mouthpiece element 42 is located immediately downstream of the tubular element 100. As shown in Fig. 1, the upstream end of the mouthpiece element 42 adjoins the downstream end 40 of the tubular element 100.

The mouthpiece element 42 is provided in the form of a cylindrical plug made of low-density cellulose acetate. The mouthpiece element 42 has a length of approximately 12 millimeters and an outer diameter of approximately 7.25 millimeters. The RTD of the mouthpiece element 42 is approximately 12 millimeters of water.

The aerosol generating article 1 comprises a ventilation zone 60 provided at a location along the tubular element 100. In more detail, the ventilation zone is provided at a distance of approximately 4 millimeters from the downstream end of the tubular element 100. The ventilation level of the aerosol generating article 1 is approximately 40 percent.

The rod 111 comprises an aerosol-generating substrate 112 of one of the types described above. The aerosol-generating substrate 112 can substantially determine the structure and dimensions of the rod 111. The rod 111 comprising the aerosol-generating substrate has an outer diameter of approximately 7.25 millimeters and a length of approximately 12 millimeters.

The aerosol-generating article 1 further comprises a wrapper 10 with a high basis weight with an embossed portion 113 surrounding a rod 111 made of an aerosol-generating substrate 112. In the embodiment of Fig. 1, the embossed portion 113 of the wrapper 10 with a high basis weight completely surrounds the rod 111 made of an aerosol-generating substrate along the circumference of the rod 111. In this embodiment, the embossed portion 113 of the wrapper 10 with a high basis weight surrounds the rod 111 made of an aerosol-generating substrate along the entire length of the rod 111.

In this embodiment, the wrapper 10 with a high basis weight extends along the entire length of the aerosol-generating article 1 from the upstream end 18 to the downstream end 20. The wrapper 10 with a high basis weight completely surrounds the upstream element 46, the rod 111 of the aerosol-generating substrate 112, the tubular element 100 and the mouthpiece 42 along their circumferences. The wrapper 10 with a high basis weight forms the outer surface of the aerosol-generating article 1.

The wrapper 10 with a high basis weight further comprises a layer of adhesive 115 on the inner surface of the wrapper 10. The illustration of the layer of adhesive 115 in Fig. 1 is intended for schematic purposes only and therefore does not show the layer of adhesive itself or its arrangement on the wrapper. The layer of adhesive 115 will be described in more detail below with respect to Figs. 7 and 8. In the embodiment of Fig. 1, the wrapper 10 with a high basis weight with the layer of adhesive 115 completely surrounds the aerosol-generating article, and the adhesive is in direct contact with the aerosol-generating article.

The representation of the embossed portion 113 in Fig. 1 is intended for diagrammatic purposes only and therefore does not show the protrusions themselves or their arrangement on the embossed portion 113. The embossed portion 113 will be described in more detail below with respect to Figs. 4 and 5.

The rod 111 of the aerosol-generating substrate 112 also comprises an elongated current-collecting element 44 inside the aerosol-generating substrate 112. In more detail, the current-collecting element 44 is arranged substantially in the longitudinal direction inside the aerosol-generating substrate 112 so as to be approximately parallel to the longitudinal direction of the rod 111. As shown in the image of Fig. 1, the current-collecting element 44 is arranged in a radial central position inside the rod and effectively extends along the longitudinal axis of the rod 111.

The current collecting element 44 extends the entire distance from the upstream end to the downstream end of the rod 111. In fact, the current collecting element 44 has substantially the same length as the rod 111 containing the aerosol-generating substrate 112.

In the embodiment according to Fig. 1, the current collecting element 44 is provided in the form of a strip and has a length of approximately 12 millimeters, a thickness of approximately 60 micrometers and a width of approximately 4 millimeters.

The upstream section 16 comprises an upstream element 46 arranged immediately upstream of the rod 111 of the aerosol-generating substrate 112, wherein the upstream element 46 is in longitudinal alignment with the rod 111 of the aerosol-generating substrate 112. In the embodiment according to Fig. 1, the downstream end of the upstream element 46 adjoins the upstream end of the rod 111 and, in particular, the upstream end of the aerosol-generating substrate 112. This advantageously prevents the current-collecting element 44 from shifting. In addition, this ensures that the user cannot accidentally touch the heated current-collecting element 44 after use.

The upstream element 46 is provided in the form of a cylindrical plug of cellulose acetate surrounded by a rigid wrapper 10. The upstream element 46 has a length of approximately 5 millimeters. The RTD of the upstream element 46 is approximately 30 millimeters of water.

The tubular element 100 comprises a tubular body 103 defining a cavity 106 extending from a first end 101 of the tubular body 103 to a second end 102 of the tubular body 103. The tubular element 100 also comprises a bent end portion defining a first end wall 104 at the first end 101 of the tubular body 103. The first end wall 104 also defines an opening 105 that provides an air flow between the cavity 106 and the outer side of the tubular element 100. In particular, the embodiment according to Fig. 1 is designed in such a way that the aerosol can flow from the rod 111 from the aerosol-generating substrate 112 through the opening 105 into the cavity 106.

The cavity 106 of the tubular body 103 is substantially empty, and therefore a substantially unrestricted air flow is possible along the cavity 106. Therefore, the RTD of the tubular element 100 can be localized in a particular longitudinal position of the tubular element 100, namely, on the first end wall 104, and can be controlled by means of a selected configuration of the first end wall 104 and its corresponding opening 105. In the embodiment of Fig. 1, the RTD of the tubular element 100 (which is essentially the RTD of the first end wall 104) is substantially 10 millimeters of water column. In the embodiment of Fig. 1, the tubular element 100 has a length of approximately 16 millimeters, an outer diameter of approximately 7.25 millimeters and an inner diameter ( _DFTS ) of approximately 6.5 millimeters. Thus, the thickness of the peripheral wall of the tubular body 103 is approximately 0.75 millimeters.

As shown in Fig. 1, the first end wall 104 extends substantially transversely to the longitudinal direction of the aerosol generating article 1 and the longitudinal direction of the tubular member 100. The opening 105 is the only opening in the first end wall 104, and the opening 105 is generally located at a radial central position of the tubular member 100. Therefore, the first end wall 104 usually has a ring-shaped shape.

The combination of the first end wall 104 and its corresponding opening 105 provides an effective barrier structure that can restrict the movement of the aerosol generating substrate, while also allowing one or both of the air and the aerosol to flow from the rod 111 of the aerosol generating substrate 112 and through the opening 105 into the cavity 106. The opening 105 is generally aligned with the radial central position of the current collecting element 44 of the rod 111 of the aerosol generating substrate 112. This may be advantageous because it helps maintain the distance between the first end wall 105 and the current collector and thus reduces unwanted heating of the first end wall 105. It may also be advantageous because it may provide a direct, unimpeded flow of aerosol downstream of the flow path created by a portion of the aerosol generating substrate in the immediate vicinity of the current collector element 44.

The first end wall 104 is formed by bending the end portion of the tubular element 100 around a bending point. The bending point typically corresponds to the first end of the tubular body 103 of the tubular element 100.

Fig. 2 shows an aerosol generating article 2 according to a second embodiment of the present invention. The aerosol generating article 2 has similarities with the aerosol generating article 1 according to the first embodiment of the present invention in Fig. 1, and, where appropriate, like reference numerals are used. However, the aerosol generating article 2 of Fig. 2 does not include a tubular element. In particular, unlike the aerosol generating article 1 of Fig. 1, the aerosol generating article 2 of Fig. 2 does not include a tubular element 100 between the rod 211 of the aerosol generating substrate 212 and the mouthpiece element 42. Instead, the aerosol generating article 2 of Fig. 2 comprises two hollow acetate tubes between the rod 211 of the aerosol-generating substrate 212 and the mouthpiece element 42. These are the first hollow acetate tube 280, located immediately downstream and in longitudinal alignment with respect to the rod 211 of the aerosol-generating substrate 212, and the second hollow acetate tube 290, located immediately downstream with respect to the first hollow acetate tube 280.

The first hollow acetate tube 280 and the second hollow acetate tube 290 form a tubular body 203 with a cavity 206 extending from a first upstream end 201 of the tubular body 203 to a second downstream end 202 of the tubular body 203.

The first hollow acetate tube 280 forms a support element. The first end of the first hollow acetate tube, located upstream, adjoins the end of the rod 211 located downstream of the substrate 212 generating the aerosol.

The second hollow acetate tube 290 forms an aerosol cooling element that is adjacent to the downstream end of the first hollow acetate tube 280.

The internal cavity 206 of the tubular body 203, formed by the first hollow acetate tube 280 and the second hollow acetate tube 290, is substantially empty, and therefore a substantially unlimited flow of air is possible along the cavity 206.

Overall, the tubular body 203 does not contribute significantly to the overall RTD of the aerosol generating article. The RTD of the tubular body 203 as a whole is substantially 0 mm H2O.

The first hollow acetate tube 280 has a length of approximately 8 millimeters, an outer diameter of approximately 7.25 millimeters, and an inner diameter (D _FTS ) of approximately 1.9 millimeters. Thus, the thickness of the peripheral wall of the first hollow acetate tube 280 is approximately 2.67 millimeters.

The second hollow acetate tube 290 has a length of approximately 8 millimeters, an outer diameter of approximately 7.25 millimeters and an inner diameter ( _DSTS ) of approximately 3.25 millimeters. Thus, the thickness of the peripheral wall of the second hollow acetate tube 290 is approximately 2 millimeters. Thus, the ratio between the inner diameter ( _DSTS ) of the first hollow acetate tube 280 and the inner diameter ( _DSTS ) of the second hollow acetate tube 290 is approximately 0.75.

The aerosol generating article 2 comprises a ventilation zone 60 provided at a location along the second hollow acetate tube 290. In more detail, the ventilation zone is provided at a distance of approximately 2 millimeters from the upstream end of the second hollow acetate tube 290. The ventilation level of the aerosol generating article 2 is approximately 25 percent.

The aerosol-generating article 2 may further comprise a wrapper 10 with a high basis weight with an embossed portion 13 surrounding a rod 211 of an aerosol-generating substrate 212. In this embodiment according to Fig. 1, the embossed portion 213 of the wrapper 10 with a high basis weight completely surrounds the rod 211 of an aerosol-generating substrate 212 along the circumference of the rod 211. In this embodiment, the embossed portion 213 of the wrapper 10 with a high basis weight surrounds the rod 211 of an aerosol-generating substrate 212 only along a portion of the length of the rod 211.

In this embodiment, the wrapper 10 with a high basis weight extends along the entire length of the aerosol-generating article 2, from the upstream end 18 to the downstream end 20. The wrapper 10 with a high basis weight completely surrounds the upstream element 46, the rod 211 of the aerosol-generating substrate 212, the first hollow acetate tube 280, the second hollow acetate tube 290 and the mouthpiece 42 along their circumferences. The wrapper 10 with a high basis weight forms the outer surface of the aerosol-generating article 2.

The representation of the embossed portion 213 in Fig. 2 is intended for schematic purposes only and therefore does not show the protrusions themselves or their arrangement on the embossed portion 213. The embossed portion 213 will be described in more detail below with respect to Figs. 4 and 5.

Fig. 3 shows an aerosol generating article 3 according to a third embodiment of the present invention. Unlike the embodiments of Fig. 1 and 2, the aerosol generating article 3 according to the third embodiment does not comprise any form of an upstream element 46 upstream of the rod 311 of the aerosol generating substrate 312. Therefore, the upstream or distal end 318 of the aerosol generating article 3 is formed by the rod 311 of the aerosol generating substrate 312. Furthermore, in the third embodiment of the present invention, the rod 311 of the aerosol generating substrate 312 does not comprise a current collecting element 44 located inside the aerosol generating substrate 312. Therefore, such an aerosol-generating article 3 may be an article that is designed with the possibility of accommodating a heating plate of an aerosol-generating device. The heating plate may be inserted into the aerosol-generating substrate 312 through the end 318 of the aerosol-generating article 3 located upstream.

The aerosol-generating article 3 according to the third embodiment has a hollow acetate tube 380 substantially the same as the first hollow acetate tube 280 of the aerosol-generating article 2 according to the second embodiment. This hollow acetate tube 380 forms a support element and has a cavity 306 extending from the upstream end of the hollow acetate tube 380 to the downstream end of the hollow acetate tube 380.

The cavity 306 of the hollow acetate tube 380 is substantially empty, and thus provides a substantially unrestricted flow of air along the cavity 306.

The hollow acetate tube 380 does not contribute significantly to the overall RTD of the aerosol generating article. The RTD of the intermediate hollow section 250 as a whole is substantially 0 mm H2O.

The aerosol generating article 3 according to the third embodiment comprises an aerosol cooling element 370 located immediately downstream of the hollow acetate tube 380, wherein the aerosol cooling element 370 is in longitudinal alignment with the rod 311 of the aerosol generating substrate 312 and the hollow acetate tube 380. In more detail, the upstream end of the aerosol cooling element 370 adjoins the downstream end of the hollow acetate tube 380.

In contrast to the aerosol cooling element (the hollow acetate tube 290) of the aerosol generating device 2, according to the second embodiment, the aerosol cooling element 370 comprises a plurality of longitudinally extending channels that provide low or substantially zero resistance to the passage of air through the rod. In more detail, the aerosol cooling element 370 is made of a preferably non-porous sheet material selected from the group consisting of a metal foil, a polymer sheet and substantially non-porous paper or cardboard. In particular, in the embodiment shown in Fig. 3, the aerosol cooling element 370 is provided in the form of a corrugated and assembled sheet of polylactic acid (PLA). The aerosol cooling element 370 has a length of approximately 8 millimeters and an outer diameter of approximately 7.25 millimeters.

The aerosol-generating article 3 may further comprise a wrapper 10 with a high basis weight with an embossed portion 313 surrounding a rod 311 of an aerosol-generating substrate 312. In this embodiment of Fig. 3, the embossed portion 313 of the wrapper 10 with a high basis weight surrounds the rod 311 of an aerosol-generating substrate around only a portion of the circumference of the rod 311. In this embodiment, the embossed portion 313 of the wrapper 10 with a high basis weight surrounds the rod 311 of an aerosol-generating substrate along the entire length of the aerosol-generating article 3.

In this embodiment, the paper wrapper 10 with a high basis weight extends along the entire length of the aerosol-generating article 3, from the upstream end 18 to the downstream end 20. The paper wrapper 10 completely surrounds the rod 311 of the aerosol-generating substrate 312, the hollow acetate tube 380, the aerosol cooling element 370, and the mouthpiece 42 along their circumferences. The paper wrapper 10 with a high basis weight forms the outer surface of the aerosol-generating article 3.

The representation of the embossed portion 313 in Fig. 3 is intended for schematic purposes only and therefore does not show the protrusions themselves or their arrangement on the embossed portion 313. The embossed portion 313 will be described in more detail below with respect to Figs. 4 and 5.

Fig. 4 and 5 respectively show a top view and a side view in section of a pattern of protrusions on an embossed portion of a wrapper 410 intended for use with an aerosol-generating article of an embodiment of the present invention. The embossed portion 13 shown in both Fig. 4 and 5 is in an unfolded state. The embossed portion 13 has a plurality of protrusions 4 arranged at a distance from each other in the form of a repeating pattern. The concavities 5 are formed by a space between each of the protrusions, where the wrapper 10 with a high basis weight has not been subjected to embossing. Each protrusion is a spherical dome. The embossed portion 13 is further defined by a pitch 6 of the protrusions 4. This pitch 6 is defined by the distance between the centers of two adjacent protrusions 4. The protrusion 4 is also defined by its depth 7. The depth 7 of the protrusion is equal to the thickness of the wrapper 10 with a large basic weight without embossing plus the height of the projection of the protrusion 4. Each protrusion has substantially the same depth, pitch and profile. The embossed portion 13 has an inner surface 401 which, when assembled, is in direct or indirect contact with the aerosol-generating article. It is the concavities 5 that are in direct or indirect contact with the aerosol-generating article. The inner surface of the protrusions 4 is located at a distance from the aerosol-generating article. The embossed portion also has an outer surface 402. The embossed portion of the wrapper 410 comprises a layer of adhesive 415 on the inner surface 401 of the wrapper 410.

The inventors conducted experimental tests to test the manufacturing capabilities of various aerosol-generating article wrappers, including aerosol-generating article wrappers according to the present invention. These tests were aimed at determining the aerosol-generating article manufacturing rates that could be achieved with wrappers having different properties. The tests focused primarily on comparing conventional aerosol-generating article wrappers known in the art with wrappers with a higher basis weight. However, other wrapper parameters were also evaluated during the tests.

The test wrappers were paper wrappers in the form of rectangular sheets of paper with an inner surface and an outer surface. The test wrappers had two transverse edges in the direction of wrapper curl and two longitudinal edges in the direction perpendicular to the direction of wrapper curl. The wrapper was wrapped around the entire circumference of the aerosol-generating article. The width of the test wrappers was greater than the circumference of the aerosol-generating articles so that the two longitudinal edges of the wrappers overlapped when the wrappers were wrapped around the articles.

During the test manufacturing process, each wrapper was wrapped around two identical portions of two separate aerosol generating articles that were joined together. The two portions of the aerosol generating article remained joined together for the test manufacturing process. The two portions of the aerosol generating article wrapped in the wrapper are known as a "double stick". As shown in Fig. 6, the test example of a double stick 6 comprises: two identical aerosol cooling elements 670 (each at a corresponding end of the stick); two identical intermediate hollow tubular sections 603, each adjacent to and abutting each aerosol cooling element 670; and one rod of aerosol generating substrate 611 in the central portion of the stick, abutting two intermediate hollow sections 603. All of these segments are wrapped in a wrapper 610 that extends along the entire length of the double stick 600. For experimental testing purposes, the properties of the wrapper 610 were varied, as discussed in more detail below. As shown in Fig. 6, each intermediate hollow tubular section 603 is formed by a first hollow acetate tube and a second hollow acetate tube of the type described above with respect to Fig. 2.

The two connected parts of the double stick can be separated from each other in an additional manufacturing process in which the double stick is cut in half along the cutting line 675 through the rod of the aerosol-generating substrate. Each resulting part of the aerosol-generating article has a mouthpiece element, an intermediate hollow section and a shorter rod of the aerosol-generating substrate. The experimental tests described herein focus on the production rate of double sticks achieved for each tested wrapper. All parameters from the experimental data are related to the double stick. In other words, the mass of glue and the production rates refer respectively to the mass of glue consumed per double pair and the number of double sticks produced per minute.

A number of other wrapper parameters were varied to evaluate their effect on production speeds. These other parameters included whether or not the wrapper was embossed across its entire surface and the amount of adhesive applied to the inside surface of the wrapper. The wrappers tested contained 5, 15, or 30 milligrams of adhesive per wrapper.

As shown in Fig. 7, in the test samples with 5 milligrams of adhesive on the wrapper 710, 5 milligrams of adhesive is applied in the form of one longitudinal strip 795. The strip of adhesive occupies a very small percentage of the inner surface of the wrapper 710 and extends substantially the entire length of the wrapper 710. When the wrapper 710 is wrapped around the segments of the article, the strip 795 remains between the overlapping edges of the wrapper 710, forming a longitudinal seam. The remainder of the inner surface of the wrapper in Fig. 7 is substantially free of adhesive.

As shown in Fig. 8, in the test samples with 15 or 30 milligrams of adhesive per wrapper, the adhesive was applied in a uniform layer over substantially the entire inner surface of the wrapper 810. In particular, the adhesive was provided in the form of two separate portions 891, 892 occupying substantially the entire inner surface of the wrapper 810. The only adhesive-free portions of the wrapper 810 were a peripheral border extending around all edges 893 of the wrapper and a strip of adhesive-free region 894 separating the two separate portions 891, 892 of adhesive.

When testing twin sticks, minor defects, such as partial opening of the wrapper at the overlap, were classified as acceptable because they did not significantly affect the manufacturing process. Defects classified as unacceptable were those that were found to significantly affect the manufacture of twin sticks. For example, if the opening at the overlap of the wrapper was too large, the machine could jam or glue could leak from the wrapper and contaminate the equipment.

The production speeds shown in Tables 2 and 3 refer to the number of twin sticks produced in good quality with minimal or no defects. The tests also included an assessment of the defects present in the twin sticks when the production speed was 500 twin sticks per minute higher than the maximum acceptable production speed that would produce good quality twin sticks. It should be noted that the production equipment used for the tests had an inherent maximum production speed of 5,000 twin sticks per minute.

Table 2: Comparison of wrapper production speeds with different parameters

Test sample No. Basis weight of paper (grams per square meter) Embossing (Yes/No) Glue (milligrams per double stick) Achieved production speed (double sticks per minute) 1 45 No 5 4500 2 78 No 5 0 3 78 No 15 1500 4 78 Yes 15 2500 5 78 Yes 30 4000

In the first experiment, the results of which are summarized in Table 2, a double stick with a traditional aerosol generating product wrapper was compared to double sticks having higher grammage wrappers with a basis weight of 78 grams per square meter.

Test Sample 1 had a conventional wrapper with a basis weight of 45 grams per square meter without embossing and 5 milligrams of adhesive per unit. Test Sample 1 achieved a production speed of 4,500 double sticks per minute, although the significant increase in defects observed when the speed was increased to 5,000 double sticks per minute was not observed.

Test Sample 2 had a high grammage wrapper with a basis weight of 78 grams per square meter without embossing and 5 milligrams of adhesive per piece. Test Sample 2 did not produce good quality double sticks at any production speed. With the higher basis weight paper used for this test, the wrapper did not adhere to itself at its overlapping portion, resulting in an unusable product. This was due to the high bending moment required to twist the wrapper and the strong springback effect of the wrapper after twisting. This test sample revealed the need for some modification of the high basis weight wrapper to overcome the high bending moment required to twist the wrapper and the strong springback effect of the wrapper after twisting.

Test Sample 3 had a wrapper identical to that of Test Sample 2, except that 15 milligrams of adhesive was applied instead of 5 milligrams, and the adhesive was applied uniformly over substantially the entire inside surface of the wrapper, as shown in Fig. 8. In this configuration, the machine speed achieved production rates of 1,500 good quality twin sticks per minute. This test sample clearly shows that the increased amount of adhesive and the increased application area have a positive effect on the production rates achieved. When the production rate was increased by 500 twin sticks per minute, the twin sticks of Test Sample 3 exhibited defects that would be sufficient to have a noticeable effect on the finished aerosol generating articles.

Test Sample 4 had a wrapper identical to that of Test Sample 3, except that the wrapper of Test Sample 4 was an embossed wrapper. This test sample achieved production speeds of 2,500 good quality double sticks per minute. This test sample clearly shows that the embossing of the wrapper has a positive effect on the production speeds that can be achieved. Even when production speeds were increased by 500 double sticks per minute, only minor defects were observed, and such minor defects were not considered sufficient to have a noticeable effect on the finished aerosol generating articles.

Test Sample 5 had a wrapper identical to that of Test Sample 4, except that: for the wrapper of Test Sample 5, the amount of adhesive applied to the inside surface of the wrapper was further increased to 30 milligrams per wrapper. A further increase in the achieved production rate was observed to 4,000 good quality double sticks per minute. Even when production rates were increased by 500 double sticks per minute, only minor defects were observed, and such minor defects were not considered sufficient to have a noticeable effect on the finished aerosol generating articles.

Four additional test specimens were tested, not shown in Table 2. All four of these additional test specimens had paper wrappers with a basis weight of 45 grams per square meter. Two of these four additional test specimens had embossed wrappers, one with 15 milligrams of adhesive per double stick and the other with 30 milligrams of adhesive per double stick. The paper wrappers of the remaining two additional test specimens were not embossed, and one had 15 milligrams of adhesive per double stick while the other had 30 milligrams of adhesive per double stick. All four additional test specimens achieved the machine's maximum production speed of 5,000 double sticks per minute with little or no defects.

The data collected in Table 2 clearly show the positive impact on the production speed and quality of the twin sticks as a result of both a) increasing the amount of adhesive applied to the inner surface of the wrapper with a higher basis weight and b) performing wrapper embossing. It was noted that the most common twin stick defect observed was the detachment of the wrapper around the central rod of the aerosol generating substrate. This can be explained by the fact that the aerosol generating substrate is a softer material than the mouthpiece sections and the intermediate hollow sections of the twin sticks. More specifically, the aerosol generating substrate provides lower resistance than the other components to the torsional pressure applied during the twisting of the wrapper around these components. As a result, the wrapper requires more force to assemble the wrapper around the substrate. Therefore, performing wrapper embossing and increased amounts of adhesive are particularly effective when surrounding the rod of the aerosol generating substrate.

Table 3: Comparison of production speeds for 65 grams per square meter wrappers with different parameters

Test sample No. Basis weight of paper (grams per square meter) Embossing (Yes/No) Glue (milligrams per double stick) Achieved production speed (double sticks per minute) 1 45 No 5 4500 6 65 No 15 1500 7 65 Yes 15 2500 8 65 No 30 3000 9 65 Yes 30 4000

In the second test, test specimen 1 was compared with additional test specimens 6 through 9, each of which had a paper wrapper with a basis weight of 65 grams per square meter. The results of the second test are shown in Table 3.

Test sample 6 had a high grammage, unembossed wrapper with a basis weight of 65 grams per square meter and 15 milligrams of adhesive applied to the inside surface. Test samples in this configuration achieved production speeds of 1,500 good quality twin sticks per minute. When the speed was increased slightly to 500 twin sticks per minute, significant defects were observed in the twin sticks, rendering them unusable.

Test Sample 7 had a wrapper identical to that of Test Sample 6, except that the wrapper of Test Sample 7 was an embossed wrapper. This resulted in production speeds increasing to 2,500 good quality twin sticks per minute. In this configuration, when production speeds were increased by 500 twin sticks per minute, only minor defects were observed that did not affect the production process. This further highlights the beneficial production effect that results from embossing the wrapper at a high basis weight.

The wrapper of Test Sample 8 was identical to that of Test Sample 6, except that the amount of adhesive applied to the inside surface of the wrapper was increased to 30 milligrams per square meter. Test Sample 8 achieved production speeds of 3,000 good quality twin sticks per minute. When production speeds were increased to 500 twin sticks per minute, only minor defects were observed that did not affect the production process. This also shows the beneficial effects of increasing the amount of adhesive applied to the inside surface of the wrapper and how this can have a beneficial effect on the production of wrappers with a higher basis weight.

The wrapper of test sample 9 was the same as that of test sample 8, except that the wrapper of test sample 9 was an embossed wrapper. In this configuration, production speeds of 4,000 good quality double sticks per minute were achieved. When the production speeds were increased to 500 double sticks per minute, only very minor defects in the double sticks were observed, which did not adversely affect production.

From the data presented in Tables 2 and 3, it is clear that both embossing the wrapper and applying a large amount of adhesive to substantially the entire inside surface of the wrapper have a beneficial effect on the production speeds that can be achieved for wrappers of high basis weight.

The combination of embossed wrapper and high adhesive content achieved the best results for both grammages of the wrappers tested. This combination of parameters most closely matches the production speeds seen with traditional wrapper, with the additional benefits of high basis weight wrapper as discussed in more detail above.

Fig. 9 shows a schematic side sectional view of an aerosol-generating article 9 according to a fourth embodiment of the present invention. The aerosol-generating article 9 has similarities with the aerosol-generating article 2 according to the second embodiment of the present invention in Fig. 2. For brevity, the repeating elements from the embodiment shown in Fig. 2 will not be repeated.

In this embodiment, the wrapper 910 surrounds the upstream element 46, the rod 911 of the aerosol-generating substrate 912, and the tubular body 903 formed by the first hollow acetate tube 980 and the second hollow acetate tube 990. The wrapper 910 does not surround the mouthpiece element 42.

In the embodiment of Fig. 9, the aerosol-generating article comprises a wrapper 910 with a high basis weight with an embossed portion 913 surrounding a rod 911 of an aerosol-generating substrate 912. In this embodiment, the embossed portion 913 of the wrapper 910 with a high basis weight completely surrounds the rod 911 of an aerosol-generating substrate 912 along the circumference of the rod 911. In this embodiment, the embossed portion 913 of the wrapper 910 with a high basis weight surrounds the rod 911 of an aerosol-generating substrate 912 along the entire length of the rod.

The aerosol generating article 9 also comprises a rim wrap 919 surrounding the mouthpiece element 42 and the second hollow acetate tube 990. The rim wrap 919 is wrapped around the mouthpiece element 42 and the outer surface of the portion of the wrap 910 surrounding the second hollow acetate tube.

Claims (15)

1. An aerosol-generating article, wherein the aerosol-generating article comprises: a plurality of segments assembled together in a longitudinal direction, wherein said plurality of segments include a rod of an aerosol-generating substrate; and a paper wrapper wrapped around said rod of an aerosol-generating substrate and at least one of said plurality of segments, wherein the paper wrapper comprises an embossed portion that surrounds the rod of an aerosol-generating substrate for at least 80 percent of the length of the rod and has a basis weight of from 50 to 100 grams per square meter; a layer of adhesive on the inner surface of the paper wrapper, wherein this layer of adhesive surrounds at least two of said plurality of segments to thereby hold said at least two segments in place relative to each other. 2. An aerosol-generating product according to claim 1, characterized in that the paper wrapper has a base weight of 60 to 70 grams per square meter. 3. An aerosol-generating product according to claim 1, characterized in that the paper wrapper has a base weight of 75 to 80 grams per square meter. 4. An aerosol generating article according to any of the preceding claims, characterized in that at least the embossed portion of the wrapper is a water-resistant wrapper. 5. An aerosol generating article according to any of the preceding claims, characterized in that the adhesive layer covers at least 50 percent of the area of the inner surface of the wrapper. 6. An aerosol-generating article according to claim 5, characterized in that the adhesive layer on the inner surface of the wrapper has a mass of 15 to 45 milligrams, preferably 20 to 40 milligrams, most preferably 25 to 35 milligrams. 7. An aerosol generating article according to any of the preceding claims, characterized in that the aerosol generating substrate rod comprises an aerosol forming substance having a glycerol content of at least 10 percent by weight. 8. An aerosol generating article according to any of the preceding claims, characterized in that the embossed portion of the wrapper directly surrounds the rod of the aerosol generating substrate. 9. An aerosol generating article according to any one of the preceding claims, characterized in that the embossed portion surrounds the rod of aerosol generating substrate over at least 90 percent of the length of the rod, more preferably over 100 percent of the length of the rod. 10. An aerosol generating article according to any one of the preceding claims, characterized in that the embossed portion of the wrapper has a bending moment of from 3 to 8 centinewton centimeters at 90 degrees, preferably from 4 to 7 centinewton centimeters, more preferably from 5 to 6 centinewton centimeters. 11. An aerosol-generating article according to any of the preceding claims, characterized in that the rod of the aerosol-generating substrate contains a gel composition. 12. An aerosol generating article according to any of the preceding paragraphs, characterized in that it further comprises an elongated susceptor element extending longitudinally through the rod of aerosol generating substrate. 13. An aerosol generating article according to any of the preceding claims, characterized in that it further comprises an upstream element provided upstream of the aerosol generating substrate rod and adjacent to the upstream end of the aerosol generating substrate rod. 14. An aerosol generating article according to any one of the preceding claims, further comprising a downstream section located downstream of the aerosol generating substrate rod and in axial alignment with the aerosol generating substrate rod, wherein the downstream section comprises one or more downstream elements. 15. A method for producing an aerosol-generating article, wherein the method comprises: providing a plurality of segments assembled together in a longitudinal direction, wherein said plurality of segments include a rod of an aerosol-generating substrate, providing a paper wrapper having a basis weight of from 50 to 100 grams per square meter; embossing a portion of the paper wrapper; applying a layer of adhesive to the inner surface of the paper wrapper and wrapping the wrapper around the rod of an aerosol-generating substrate and at least one other of said plurality of segments so that the embossed portion surrounds at least the rod of an aerosol-generating substrate for at least 80 percent of the length of the rod, and so that the layer of adhesive surrounds at least two of said plurality of segments to thereby hold said at least two segments in place relative to each other.