RU2847262C1 - Aerosol-generating article having wrapper - Google Patents

Abstract

FIELD: smoking accessories.

SUBSTANCE: invention relates to an aerosol-generating article. Aerosol-generating article for producing an inhalable aerosol when heated, comprises: a rod of an aerosol-generating substrate, wherein the rod of the aerosol-generating substrate has an aerosol-forming agent content of at least 5 percent, based on the dry weight; and a wrapper wrapped around at least a portion of the aerosol-generating article, wherein the wrapper comprises an embossed portion surrounding at least a core of an aerosol-generating substrate, wherein the embossed part of the wrapper surrounds the rod of the aerosol-generating substrate along at least 80 percent of the length of the rod.

EFFECT: increased water resistance and heat resistance are provided along the surface of the embossed portion of the wrapper by reducing the surface area of the embossed portion of the wrapper in contact with the aerosol-generating substrate rod.

17 cl, 5 dwg, 1 tbl

Description

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

Combustible aerosol-generating products, such as cigarettes, typically contain a cylindrical rod of shredded tobacco filler surrounded by a wrapper and a cylindrical filter, axially aligned and closely 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 wrapper, usually made of paper, which encircles the entire length of the filter and the adjacent portion of the tobacco rod. The user uses the cigarette by lighting one end, burning the shredded tobacco rod. The smoker then draws the main stream of smoke into their mouth by inhaling from the mouthpiece or filter end of the cigarette.

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

A number of prior art documents disclose aerosol-generating devices for consuming aerosol-generating articles. 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 that comprise an internal heater plate that is adapted for insertion into an aerosol-generating substrate. Alternatively, document WO 2015/176898 proposes inductively heated aerosol-generating articles comprising an aerosol-generating substrate and a current-receiving (susceptor) element located within the aerosol-generating substrate.

It's common knowledge that the aerosol-generating substrate is wrapped in a wrapper. The wrapper can help hold the aerosol-generating substrate in place. The wrapper can also provide a barrier between the aerosol-generating substrate and the user. It's common knowledge that thicker wrappers can be more effective in these functions. However, thicker wrappers can present difficulties when it comes to manufacturing and assembling aerosol-generating products.

Therefore, it would be desirable to provide a wrapper that is sufficient to hold the aerosol-generating substrate in place while also being suitable for high-speed manufacturing. Currently, there are limitations in the variety of wrapper materials and properties that can be used for such purposes. It would also be desirable to minimize interaction between the wrapper and the aerosol-generating substrate, as this, in turn, minimizes interaction between the user and the aerosol-generating substrate.

The present invention relates to an aerosol-generating article for producing an inhalable aerosol upon heating. The aerosol-generating article may comprise a rod of an aerosol-generating substrate. The rod of the aerosol-generating substrate may comprise an aerosol-forming substance. The aerosol-generating article may further comprise a wrapper wrapped around at least a portion of the aerosol-generating article. The wrapper may comprise an embossed portion. The embossed portion may surround at least the rod of the aerosol-generating substrate.

According to the present invention, an aerosol-generating article is provided for producing an inhalable aerosol upon heating, wherein the aerosol-generating article comprises: a rod of an aerosol-generating substrate containing an aerosol-forming substance; and a wrapper wrapped around at least a portion of the aerosol-generating article. The wrapper comprises an embossed portion surrounding at least the rod of the aerosol-generating substrate.

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 the user. For the purposes of this document, the term "aerosol-generating substrate" refers to a substrate capable of releasing volatile compounds when heated to generate an aerosol.

A conventional cigarette is ignited 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 oxygen in the air drawn through the cigarette causes the end of the cigarette to ignite, and the resulting combustion generates inhaled smoke. In 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 heat transfer from a combustible fuel element or heat source to a physically separate aerosol-generating material. For example, the aerosol-generating articles according to the present invention find particular application in aerosol-generating systems comprising an electrically heated aerosol-generating device having an internal heating plate adapted for insertion into the aerosol-generating substrate rod. 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," "proximal," and "downstream" are used to describe the relative positions of components or portions of components of an aerosol-generating system. Aerosol-generating systems according to the invention have a proximal end through which, during use, the aerosol exits the system for delivery to the user, and an opposite distal end. The proximal end of the aerosol-generating article may also be referred to as the mouthpiece end. During use, the user draws on the proximal end of the aerosol-generating article to inhale the aerosol generated by the aerosol-generating article. The terms "upstream" and "downstream" refer to the direction of aerosol movement through the aerosol-generating article when the user draws on the proximal end.

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

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

The term "length" refers to the longitudinal dimension of an aerosol-generating component. For example, it can be used to describe 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 the aerosol-generating substrate to maintain the shape of the aerosol-generating substrate and is made of paper or other material and optional filler materials.

In the context of this document, the terms "inner" and "outer" when describing the surfaces of the wrapper refer to the orientation of the wrapper relative to the aerosol-generating article. The wrapper may be wrapped such that the inner surface of the wrapper faces the aerosol-generating article, and the outer surface faces away from the aerosol-generating article.

The term "bulge" is used in this document to refer to protrusions formed on the surface of the wrapper. These protrusions may be cut, molded, or stamped onto the wrapper. The portion of the wrapper containing such protrusions is called "embossed." Sections of the wrapper that do not form a protrusion 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 exhibits 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, typically measured using a liquid, where the liquid/vapor interface meets a solid surface. Quantitatively, it represents 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. The result is reported as the contact angle at the interface, expressed in degrees, and can range from near zero to nearly 180 degrees.

The wrapper of the present invention provides an improved component for an aerosol-generating article. By providing the wrapper with an embossed portion surrounding at least a rod of an aerosol-generating substrate, the interaction between the inner surface of the wrapper and the rod of the aerosol-generating substrate can be reduced. For example, the embossed portion can reduce the amount of contact between the inner surface of the wrapper and the rod of the aerosol-generating substrate. This can advantageously help reduce the degree to which moisture can be transferred between the rod of the aerosol-generating substrate and the wrapper. This can also advantageously help reduce the degree to which heat can be transferred between the rod of the aerosol-generating substrate and the wrapper.

The configuration of the wrapper of the present invention can also advantageously contribute to reducing the degree to which heat can be transferred between the rod of the aerosol-generating substrate and the 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 can 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 core, it is possible to wrap one or both of the thicker wrapper and the wrapper with a higher basis weight around the aerosol-generating substrate core while still ensuring high-speed production of the aerosol-generating article. This is because the embossed portion of the wrapper can impart the same bending and twisting properties to the thicker wrapper as to a standard wrapper.

By providing a thicker wrapper around the aerosol-generating substrate rod, the structural integrity of the aerosol-generating product can be maintained. This is because a thicker wrapper can be more resistant to one or both of the moisture and heat emitted by the heated aerosol-generating substrate rod. This makes the aerosol-generating product less prone to deformation during use.

Additionally, by providing a wrapper with an embossed portion, the structural integrity of the aerosol-generating article can be further improved. This is because 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 wrapper and the core of the aerosol-generating article may also help reduce the likelihood of transferring one or both of moisture and heat from the aerosol-generating substrate to the outside of the aerosol-generating article.

An 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 greater than conventional aerosol-generating article wrappers, as is well 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. A wrapper with a higher basis weight may slow or reduce the transfer of one or both 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 between 50 grams per square meter and 100 grams per square meter.

An aerosol-generating article may comprise multiple segments or components. Multiple segments or components may be assembled together longitudinally. Multiple segments may be assembled into a rod. Multiple segments may include a rod made of an aerosol-generating substrate. Multiple segments may include one or more of the following components, each 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 made of fibrous filter material, such as cellulose acetate. The filter segment may be a hollow tube made 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. The paper wrapper may therefore 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 wraps around all segments of the aerosol-generating article. In some embodiments, the paper wrapper wraps around only some of the segments of the aerosol-generating article. Preferably, the paper wrapper wraps 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.

As noted above, the wrapper may comprise an embossed portion surrounding 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 water-resistant. Water-resistant wrap can provide an additional barrier against moisture from the aerosol-generating substrate core. The embossed portion may have a water-resistant inner surface. When the inner surface of the embossed portion of the wrapper is water-resistant, moisture from the aerosol-generating substrate core can be prevented from penetrating into the wrapper. This can help reduce swelling, visible soiling, and physical weakening of the wrapper. It can also help maintain the structural integrity of the aerosol-generating product. Reducing or preventing swelling of the aerosol-generating product can improve the usability of the aerosol-generating product, allowing for reliable insertion and removal of the aerosol-generating product from the heating device with a reduced risk of damage to the aerosol-generating product.

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 using a liquid, where the liquid/vapor interface meets a solid surface. It quantitatively represents 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. The result is expressed as the contact angle at the interface and is specified in degrees. It can range from near 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 the aerosol-generating substrate core. Where the embossed portion of the wrapper directly surrounds the aerosol-generating substrate core, the embossed portion of the wrapper is in direct contact with the core of the aerosol-generating article.

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

The embossed portion of the wrapper may completely surround the aerosol generating substrate rod along the circumference of the rod.

The embossed portion of the wrapper may surround the aerosol-generating substrate rod only around a portion of the rod's circumference. In cases where the embossed portion of the wrapper surrounds the aerosol-generating substrate rod only around a portion of the rod's circumference, the embossed portion of the wrapper may surround the aerosol-generating substrate rod around no more than 80 percent of the rod's circumference. In cases where the embossed portion of the wrapper surrounds the aerosol-generating substrate rod only around a portion of the rod's circumference, the embossed portion of the wrapper may surround the aerosol-generating substrate rod around at least 20 percent of the rod's circumference.

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

The embossed portion of the wrapper may extend along the entire length of the wrapper. The embossed portion 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 wrapper's length. 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 wrapper's length.

The embossed portion of the wrapper may have a convex outer surface and a concave inner surface. The convex outer surface may have one or more protrusions that project and are spaced apart from the plane of the wrapper. This reduces the surface area of the embossed portion of the wrapper in contact with the aerosol-generating substrate core. This may help provide increased resistance to one or both moisture and heat from the aerosol-generating substrate. The concave inner surface may have one or more concavities that correspond to the area or areas where the wrapper is not 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 the aerosol-generating substrate core. The plane of the wrapper is obtained when the wrapper is unfolded.

The embossed portion of the wrapper may have a basis weight that is greater than that of conventional wrappers for aerosol-generating articles, as is well known in the art. A thicker wrapper may slow or reduce the transmission of one or both moisture and heat through the wrapper. This may help maintain the structural integrity of the aerosol-generating article and further enhance the wrapper's resistance to one or both moisture and heat from the aerosol-generating substrate core. 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 multiple embossments, each embossment 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 embossment may also have a pitch of 0.2 millimeters to 0.4 millimeters, preferably 0.25 millimeters to 0.35 millimeters, and 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 wrapping line may range from 30 degrees to 60 degrees. Multiple embossments may be spaced apart in a repeating pattern. This repeating pattern, with spaced embossments of substantially uniform depth, pitch, and profile, can help ensure uniform water and heat resistance properties across the surface of the embossed portion of the wrapper.

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 a 90-degree bend. Preferably, the embossed portion of the wrapper has an angle memory of 15 degrees to 35 degrees after a 90-degree bend. More preferably, the embossed portion of the wrapper has an angle memory of 20 degrees to 30 degrees after a 90-degree bend.

The bending moment and tilt angle memory of the wrapper are measured in accordance with the Schlenker bending stiffness test in accordance with DIN 53864 (August 1978) using a suitable bending strength testing apparatus, such as that supplied by Frank Prufgerate Gmbh. According to DIN 53864, the bending moment is the torsional moment required to bend the test specimen (paper material) to a specified angle (90 degrees) with a specified clamp length (20 millimeters). The tilt angle memory is the residual angle of the test specimen after the test at the bending moment. A large angle indicates 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 incorporating an embossed wrapper section with the bending and twisting properties defined above, it may be possible to wrap a thicker wrapper around an aerosol-generating substrate rod while still ensuring high-speed production of the aerosol-generating article.

An aerosol-generating article according to the present invention may comprise a rod of an aerosol-generating substrate. The rod of the 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 aerosol-generating substrate may comprise a gel composition that includes nicotine.

The aerosol-generating substrate rod may contain one or more aerosol formers. Upon vaporization, the aerosol former may transfer other vaporizable compounds released from the aerosol-generating substrate rod upon heating, such as nicotine and flavorings, into the aerosol. Suitable aerosol formers 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 by weight on a dry weight basis, such as from about 10 percent to about 25 percent by weight on a dry weight basis, or from about 15 percent to about 20 percent by weight on a dry weight basis.

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

The aerosol-generating substrate rod may have an aerosol-forming agent content of from about 1 percent to about 5 percent by weight 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 agents from the aerosol-generating substrate in the aerosol.

The aerosol-generating substrate may have an aerosol-forming agent content of from about 30 percent by weight to about 45 percent by weight. This relatively high level of aerosol-forming agent is particularly suitable for 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 percent by weight to about 10 percent by weight of a cellulose ether on a dry weight basis and from about 5 percent by weight to about 50 percent by weight of additional cellulose on a dry weight basis. It has been found that the use of a combination of a cellulose ether and additional cellulose provides particularly effective aerosol delivery when used in an aerosol-generating substrate having an aerosol-forming agent content of from 30 percent by weight to 45 percent by weight.

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.

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

The gel composition described herein can be combined with an aerosol-generating device to deliver nicotine aerosol to the lungs at inhalation or airflow rates within the range of inhalation or airflow rates during normal smoking. The aerosol-generating device can continuously heat the gel composition. The user can take multiple inhalations, or "puffs," with each "puff" delivering a specific amount of nicotine aerosol. The gel composition can be capable of delivering a high-nicotine/low-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 varying environmental conditions. A stable gel may not release (release moisture) or absorb water when exposed to standard temperature and pressure with relative humidity varying from approximately 10 percent to approximately 60 percent. For example, a stable gel may substantially maintain its shape and mass when exposed to standard temperature and pressure with relative humidity varying from approximately 10 percent to approximately 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 can 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 a heterocyclic ring. In nature, alkaloid compounds are found primarily in plants and are particularly 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 comprises 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 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). For the purposes of this disclosure, the term "cannabinoid compounds" is used to describe both naturally occurring and synthetically produced cannabinoid compounds.

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

The gel composition may contain a majority of an aerosol forming agent. The gel composition may contain a mixture of water and an aerosol forming agent, wherein the aerosol forming agent forms a majority (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 constitute 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 comprise a majority of glycerol. The gel composition may comprise a mixture of water and glycerol, wherein glycerol forms the 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 further comprises 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, forms a solid medium or support matrix uniformly, resulting in the formation of a gel, in an amount of approximately 0.3 percent by weight. Gelling agents include, but are not limited to, gelling agents that provide cross-linking via hydrogen bonds and gelling agents that provide cross-linking via ionic bonds.

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

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

The gelling agent providing cross-linking via hydrogen bonds may comprise one or more of galactomannan, gelatin, agarose, konjac gum, or agar. The gelling agent providing cross-linking via hydrogen bonds preferably comprises agar.

The gel composition preferably contains a gelling agent that provides cross-linking through hydrogen bonds in the 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 ionic crosslinking may comprise low-acyl gellan, pectin, kappa-carrageenan, iota-carrageenan, or alginate. The gelling agent providing ionic crosslinking 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-enhancing agent. The viscosity-enhancing agent, in combination with a gelling agent that provides hydrogen bonding and a gelling agent that provides ionic bonding, appears to unexpectedly maintain a solid environment and preserve the gel composition, even if the gel composition contains high levels 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 at 0.3 percent by weight, increases the viscosity without causing gelation, 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 contain 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 contain 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) can promote gelling of compositions that contain gelling agents, such as, for example, a gelling agent that provides cross-linking through ionic bonds. The ionic effect can 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 (e.g., 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 amount of water. The gel composition is more stable if the composition contains some amount of 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 contains 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 advantage of a porous medium filled with a gel composition is that the gel composition is retained within the porous medium, which can facilitate the manufacture, storage, or transportation of the gel composition. This can help maintain the desired shape of the gel composition, particularly 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 containing or retaining the gel composition. Ideally, the porous medium may allow the gel composition to move within it. The porous medium may comprise natural, 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 may be split. The corrugation or splitting process may occur before or after filling with the gel composition.

Corrugating sheet material has the advantage of improving the structure to provide passages through it. Passages through the corrugated sheet material facilitate gel filling, gel retention, and fluid flow through the corrugated sheet material. Therefore, there are advantages to using 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 readily 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 the gel. The sheet material may help stabilize the structure of the tubular element containing the gel. The sheet material may facilitate the transport 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 can be a thread. The thread can contain, for example, cotton, paper, or acetate. The thread can also be filled with a gel, like any other porous medium. The advantage of using thread as a porous medium is that it can facilitate easy fabrication.

The thread can be filled with gel using any known means. The thread can be simply coated with gel, or the thread can be impregnated with gel. During manufacturing, the threads can be impregnated with gel and stored ready for use in the tubular assembly.

The porous medium filled with the gel composition is preferably provided within a tubular element that forms part of the aerosol-generating article. Ideally, the tubular element should be longer in longitudinal length than in width, but this need not be the case, as it can be one part of a multi-component element, which ideally will be longer in longitudinal length than in width. The tubular element is typically cylindrical, but this need not be the case. For example, the tubular element may have an oval, polygonal (e.g., triangular or rectangular), or any other 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 water-resistant. 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 or both sides of the wrapper. Water resistance will help maintain structure, rigidity, or strength. It can also help prevent gel or liquid leakage, especially when using flowable gels.

The aerosol-generating article may be provided with an upstream element located 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 can be heated using an internal heating plate in an electrically heated aerosol-generating device adapted for insertion into the aerosol-generating substrate. The aerosol-generating substrate can be inductively heated using a current-collecting 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 within 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 rod made of the aerosol-generating substrate, 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 rod made of the aerosol-generating substrate. 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 upstream of 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 airflow along its longitudinal axis. In particular, the term "tubular" will be used hereinafter to refer to a tubular element having a substantially cylindrical cross-section and defining 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 path. This means that the hollow tubular segment provides a negligible resistance to draw (RTD). Therefore, the flow path must be free of any components that could restrict longitudinal airflow. Preferably, the flow path is substantially empty.

An aerosol-generating article may comprise a ventilation zone located along a downstream section. More specifically, the aerosol-generating article may comprise a ventilation zone located along an aerosol-cooling element. The aerosol-cooling element may be formed as or comprise a hollow tubular segment, wherein the ventilation zone is located along the hollow tubular segment of the aerosol-cooling element.

The inventors of the present invention have discovered that satisfactory cooling of the aerosol flow generated by heating an aerosol-generating substrate and drawn through one such aerosol-cooling element is achieved by providing a ventilation zone at a location along a hollow tubular segment. Furthermore, the inventors have discovered that, as will be described in more detail below, by arranging the ventilation zone at a precisely defined 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 entry of ventilation air into the article.

The aerosol-generating substrate rod may further comprise a current-collecting element. The current-collecting element may be elongated. Preferably, the current-collecting element extends longitudinally within 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 may be positioned substantially longitudinally within the rod of the aerosol generating substrate and may 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 within a fluctuating electromagnetic field, eddy currents induced in the susceptor element cause the susceptor element to heat up. Because 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 located substantially longitudinally within the rod. This means that the length of the elongated current-collecting element is approximately parallel to the rod's longitudinal direction, for example, within plus or minus 10 degrees parallel to the rod's longitudinal direction. The elongated current-collecting element can be located in a radial central position within the rod and extends along the rod's longitudinal axis.

Preferably, the current-collecting element extends the entire distance to the downstream end of the aerosol-generating article's rod. The current-collecting element may extend the entire distance to the upstream end of the aerosol-generating article's rod. 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-receiving 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-receiving 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 susceptor 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 susceptor 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 susceptor 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 about 1 millimeter to about 5 millimeters.

The current collecting element may typically have a thickness of approximately 0.01 millimeters to approximately 2 millimeters, for example, from approximately 0.5 millimeters to approximately 2 millimeters. The current collecting element preferably has a thickness of approximately 10 micrometers to approximately 500 micrometers, more preferably from approximately 10 micrometers to approximately 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 is in the form of a strip or plate, the strip or plate is preferably rectangular with a width of approximately 2 millimeters to approximately 8 millimeters, more preferably from approximately 3 millimeters to approximately 5 millimeters. As an example, a current collecting element in the form of a strip or plate may have a width of approximately 4 millimeters.

If the current collecting element is in the form of a strip or plate, the strip or plate is preferably rectangular and has a thickness of approximately 0.03 millimeters to approximately 0.15 millimeters, more preferably from approximately 0.05 millimeters to approximately 0.09 millimeters. As an example, a current collecting element in the form of a strip or plate may have a thickness of approximately 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 collector may have a thickness of approximately 57 micrometers to approximately 63 micrometers. Even more preferably, the elongated current collector has a thickness of approximately 58 micrometers to approximately 62 micrometers. The elongated current collector may have a thickness of approximately 60 micrometers.

Preferably, the elongated current-collecting element may have a length 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 can 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-collecting element may comprise or consist of a ferromagnetic material, such as a ferromagnetic alloy, ferritic iron, ferromagnetic steel, or stainless steel. A suitable current-collecting element may be made of or comprise aluminum. Preferred current-collecting elements may be formed from 400-series stainless steels, such as type 410, type 420, or type 430 stainless steel. Different materials will dissipate different amounts of energy when located within electromagnetic fields of similar frequency and field strength.

Thus, all parameters of the current collector element, such as material type, length, width, and thickness, can be adjusted to ensure the desired power dissipation within a known electromagnetic field. Preferred current collector elements can be heated to temperatures exceeding 250 degrees Celsius.

Suitable current-collecting elements may comprise a non-metallic core with a metallic layer disposed on the non-metallic core, for example, with metallic 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, enclosing the current-collecting element. The current-collecting element may comprise a protective coating formed of glass, ceramic, or an inert metal, formed over the core material of the current-collecting element.

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

The current-collecting element may be a current-collecting element composed 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 below 500 degrees Celsius. The first current-collecting element material is preferably used primarily to heat 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 primarily to indicate 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. Therefore, 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 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 first and second Curie temperatures different from each other, it is possible to separate the heating of the aerosol-generating substrate and to control the heating temperature. The first current-receiving element material is preferably a magnetic material having a Curie temperature higher than 500 degrees Celsius. From the standpoint 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 below 400 degrees Celsius, preferably below 380 degrees Celsius or below 360 degrees Celsius. Preferably, the second material of the current-collecting element is a magnetic material selected such 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 be approximately the same as the temperature to which the current-collecting element must be heated to generate an aerosol from the aerosol-generating substrate. The second Curie temperature may, for example, be within the range of 200 degrees Celsius to 400 degrees Celsius or 250 degrees Celsius to 360 degrees Celsius. The second Curie temperature of the second material of the current-collecting element may, for example, be selected such that, when heated by a current-collecting element at a temperature equal to the second Curie temperature, the overall average temperature of the aerosol-generating substrate does not exceed 240 degrees Celsius.

An aerosol-generating product may contain a ventilation zone. The aerosol-generating product may have a ventilation rate of at least approximately 5 percent.

The term "ventilation level" is used throughout this description to denote the volumetric ratio between the airflow admitted to the aerosol-generating device 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.

An 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, and even more preferably about 35 percent or less.

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

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

The formation of an aerosol from a gaseous mixture containing various chemical compounds depends on the subtle interplay of nucleation, evaporation, condensation, and droplet coalescence, while simultaneously accounting for 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 cohesive for a long time with a reasonable probability (e.g., 50/50 probability). These molecules represent a 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, while larger clusters are generally more likely to grow. Such a critical cluster is identified as the key nucleation nucleus, from which droplet growth is expected due to the condensation of molecules from the vapor. Primary droplets, which have just formed, are assumed to emerge 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. This helps to consider that evaporation and condensation are two sides of the same mechanism: mass transfer between gas and liquid. While evaporation refers to the net mass transfer from liquid droplets to the gas phase, condensation is the net mass transfer from the gas phase to the droplet phase. Evaporation (or condensation) will cause a decrease in volume (or growth) of droplets, but will not change the number of droplets.

In this scenario, which may be further complicated by droplet coalescence, temperature and cooling rate may play a significant role in determining the system's response. In general, different cooling rates may lead to significantly different temporal behavior regarding liquid phase (droplet) formation, as the nucleation process is typically nonlinear. Without being limited by theory, it is hypothesized 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. Furthermore, it may be that higher cooling rates may promote an earlier onset of nucleation. In contrast, a decrease in the cooling rate may have a beneficial effect on the final size attained by aerosol droplets.

The inventors of the present invention unexpectedly discovered that the impact of dilution on aerosol, which can be assessed by measurement, in particular the impact on the delivery of an 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. Specifically, it was found that ventilation levels from 25 percent to 50 percent, and even more preferably from 28 to 42 percent, lead to particularly satisfactory glycerol delivery values. At the same time, nucleation time and, consequently, the delivery of nicotine and an aerosol-forming substance (such as glycerol) are improved.

The present inventors have surprisingly discovered how the beneficial effect of improved nucleation, facilitated by rapid cooling caused by the introduction of ventilation air into the product, can significantly counteract the less desirable effects of dilution. Thus, satisfactory aerosol delivery values are consistently achieved by aerosol-generating products 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 overall length of the aerosol-generating article according to the present invention is at least about 38 millimeters. More preferably, the overall length of the aerosol-generating article according to the present invention is at least about 40 millimeters. Even more preferably, the overall length of the aerosol-generating article according to the present invention is at least about 42 millimeters.

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

The overall 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 overall 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 overall 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 of less than or equal to approximately 12 millimeters. More preferably, the aerosol-generating article has an outer diameter of less than or equal to approximately 10 millimeters. Even more preferably, the aerosol-generating article has an outer diameter of 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 from about 6 millimeters to about 12 millimeters, more preferably from 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 from about 6 millimeters to about 10 millimeters, more preferably from 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 from about 6 millimeters to about 8 millimeters, more preferably from 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 approximately 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 approximately 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 approximately 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 mouthpiece 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.

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

Ensuring the placement of components such that the center of mass is closer to the upstream end than to the downstream end can result in the aerosol-generating device having a weight imbalance with the heavier upstream end. This weight imbalance can advantageously provide tactile feedback to the user, allowing them to distinguish 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, an upstream element, a rod made of an aerosol generating substrate positioned immediately downstream of the upstream element, a support element positioned immediately downstream of the rod made of an aerosol generating substrate, an aerosol cooling element positioned immediately downstream of the support element, a mouthpiece element positioned 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 be approximately 5 millimeters long, the aerosol-generating article's stem may be approximately 12 millimeters long, the support element may be approximately 8 millimeters long, and the mouthpiece element may be approximately 12 millimeters long. 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-collecting element positioned substantially longitudinally within a rod of aerosol-generating substrate and may be in thermal contact with the aerosol-generating substrate. The current-collecting 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 may have a thickness of approximately 60 micrometers.

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

a rod of aerosol-generating substrate, wherein the rod of aerosol-generating substrate optionally has an aerosol-forming substance content of at least about 5 percent on a dry weight basis; and

a wrapper wrapped around at least a portion of the aerosol-generating article, wherein the wrapper comprises an embossed portion surrounding at least a rod of the aerosol-generating substrate.

EX2. An aerosol-generating article according to EX1, wherein the aerosol-forming substance has a glycerol content of at least about 10 percent by weight.

EX3. An aerosol-generating article in accordance with EX1 or EX2, wherein the embossed portion of the wrapper is a water-resistant wrapper.

EX4. An aerosol-generating article according to any of EX1-EX3, wherein the embossed portion of the wrapper directly surrounds the rod of the aerosol-generating substrate.

EX5. An aerosol-generating article according to any of EX1-EX4, wherein the embossed portion completely surrounds the rod of the aerosol-generating substrate around the circumference of the rod.

EX6. An aerosol-generating article according to any one of EX1-EX5, wherein the embossed portion surrounds the rod of aerosol-generating substrate along at least 80 percent of the length of the rod, preferably along at least 90 percent of the length of the rod, more preferably along 100 percent of the length of the rod.

EX7. An aerosol-generating article according to any of EX1-EX6, wherein the embossed portion of the wrapper has a convex outer surface and a concave inner surface.

EX8. An aerosol-generating article according to any of EX1-EX7, wherein the embossed portion of the wrapper has a basis weight of from 50 grams per square meter to 100 grams per square meter, preferably from 60 grams per square meter to 90 grams per square meter, most preferably from 75 grams per square meter to 80 grams per square meter.

EX9. An aerosol-generating article as defined in any of EX1-EX8, wherein the embossed portion of the wrapper has a plurality of convexities.

EX10. An aerosol-generating article in accordance with EX9, wherein each protrusion has a depth of between 0.07 millimetres and 0.21 millimetres.

EX11. An aerosol-generating article in accordance with EX9 or EX10, wherein each protrusion has a pitch of between 0.2 millimetres and 0.4 millimetres.

EX12. An aerosol generating article as defined in any of EX9-EX11, wherein each protuberance is a spherical dome.

EX13. An aerosol-generating product in accordance with EX12, wherein the angle between the tangent to the spherical dome and the intersection with the horizontal wrapping line is between 30 degrees and 60 degrees.

EX14. An aerosol-generating article according to any of EX9-EX13, wherein a plurality of protrusions are provided spaced apart in a repeating pattern.

EX15. An aerosol-generating article according to any of EX1-EX14, 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.

EX16. An aerosol-generating article according to any of EX1-EX15, 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.

EX17. An aerosol-generating article according to any of EX1-EX16, wherein the aerosol-generating substrate rod comprises a gel composition.

EX18. An aerosol-generating article according to EX17, wherein the gel composition comprises at least one gelling agent and at least one of an alkaloid compound and a cannabinoid compound.

EX19. An aerosol-generating article according to EX17 or EX18, wherein the gel composition contains an aerosol-forming substance.

EX20. An aerosol-generating article according to any of EX1-EX19, wherein the aerosol-generating substrate rod comprises a plug of a porous medium filled with a gel composition.

EX21. An aerosol-generating article in accordance with EX20, wherein the porous medium is in the form of a corrugated sheet.

EX22. An aerosol-generating article in accordance with EX20 or EX21, wherein the porous medium contains cotton fibres.

EX23. An aerosol-generating article according to any of EX20-EX22, wherein the gel composition contains at least 1 percent by weight nicotine.

EX24. An aerosol-generating article according to any of EX16-EX22, wherein the gel composition further comprises an acid.

EX25. An aerosol-generating article according to any of EX17-EX24, wherein the gel composition comprises from 1 percent by weight to 6 percent by weight of at least one gelling agent.

EX26. An aerosol-generating article according to any of EX1-EX26, further comprising an elongated current-collecting element extending longitudinally through the rod of the aerosol-generating substrate.

EX27. An aerosol-generating article according to any of EX1-EX26, 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.

EX28. An aerosol-generating article according to any of EX1-EX27, 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.

EX29. An aerosol generating article in accordance with EX27 or EX28, wherein the upstream element comprises a plug of fibrous filter material.

EX30. An aerosol-generating article in accordance with any of EX27-EX28, wherein the upstream element has a draw resistance of at least 20 millimetres of water column.

EX31. An aerosol generating article according to any of EX28-EX30, wherein the downstream section comprises a mouthpiece element comprising a mouthpiece filter segment formed from a fibrous filter material.

EX32. An aerosol-generating article in accordance with EX31, wherein the draw resistance of the upstream element is at least 1.5 times greater than the draw resistance of the mouthpiece element.

EX33. An aerosol generating article according to EX31 or EX32, 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, wherein the aerosol cooling element comprises a hollow tubular segment defining a longitudinal cavity providing an unobstructed flow channel.

EX34. An aerosol generating article according to EX33, 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 defining a longitudinal cavity providing an unobstructed flow channel.

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 embossed portions of a wrapper for use with an aerosol-generating article of an 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 made of an aerosol-generating substrate 112 and a downstream section 114 at a location downstream of the rod 111 made 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 made of an aerosol-generating substrate 112. Thus, the aerosol-generating article 1 extends from an upstream or distal end 18 to a downstream or mouthpiece end 20.

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

The downstream section 114 comprises a tubular element 100 positioned 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.

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.

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 rod 111. Rod 111, containing 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 an embossed portion 113 surrounding a rod 111 of an aerosol-generating substrate 112. In the embodiment of Fig. 1, the embossed portion 113 of the wrapper 10 completely surrounds the rod 111 of an aerosol-generating substrate along the circumference of the rod 111. In this embodiment, the embossed portion 113 of the wrapper 10 surrounds the rod 11 of an aerosol-generating substrate along the entire length of the rod 111.

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

The representation of the embossed portion 113 in Fig. 1 is for schematic 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 within the aerosol-generating substrate 112. In more detail, the current-collecting element 44 is located substantially in the longitudinal direction within the aerosol-generating substrate 112 in such a way 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 located in a radial central position within 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 of 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, which is positioned 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 is adjacent to the upstream end of the rod 111 and, in particular, to 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 consumer cannot accidentally touch the heated current-collecting element 44 after use.

The upstream element 46 is provided in the form of a cylindrical plug made 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 air flow between the cavity 106 and the outside 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 unlimited air flow is possible along the cavity 106. Therefore, the RTD of the tubular element 100 can be localized in a specific longitudinal position of the tubular element 100, namely, on the first end wall 104, and can be controlled by means of the 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. 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 across the longitudinal direction of the aerosol-generating article 1 and the longitudinal direction of the tubular element 100. The opening 105 is the only opening in the first end wall 104, and the opening 105 is generally located in the radial central position of the tubular element 100. Therefore, the first end wall 104 typically has an annular 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 created by a portion of the aerosol-generating substrate in close proximity to 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 first element 100 and the mouthpiece element 42. Instead, the aerosol generating article 2 of Fig. 2 comprises two hollow acetate tubes between the first element 100 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 upstream end of the first hollow acetate tube is connected to the downstream end of the rod 211 made of the aerosol-generating substrate 212.

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, tubular body 203 does not contribute significantly to the overall RTD of the aerosol-generating article. The RTD of tubular body 203 as a whole is essentially 0 mmH2O.

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 (D _STS ) 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 (D _FTS ) of the first hollow acetate tube 280 and the inner diameter (D _STS ) 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 10 is approximately 25 percent.

The aerosol-generating article 2 may further comprise a wrapper 10 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 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 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 extends along the entire length of the aerosol-generating article 2, from the upstream end 18 to the downstream end 20. The wrapper 10 completely surrounds the upstream element 46, the rod 211 made 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 forms the outer surface of the aerosol-generating article 2.

The representation of the embossed portion 213 in Fig. 2 is 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 contain any form of an upstream element 46 located 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 contain the current collecting element 44 located inside the aerosol generating substrate 312. Therefore, such an aerosol-generating article 3 may be an article that is configured to accommodate a heater plate of an aerosol-generating device. The heater plate may be inserted into the aerosol-generating substrate 312 through an upstream end 318 of the aerosol-generating article 3.

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 supporting 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 essentially 0 mmH2O.

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 is adjacent to the downstream end of the hollow acetate tube 380.

In contrast to the aerosol cooling element (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 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 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 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 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 forms the outer surface of the aerosol-generating article 3.

The representation of the embossed portion 313 in Fig. 3 is 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 cross-sectional view of a pattern of convexities on an embossed portion of a wrapper 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 convexities 4 arranged at a distance from each other in the form of a repeating pattern. The concavities 5 are formed by the space between each convexity, where the wrapper 10 has not been embossed. Each convexity is a spherical dome. The embossed portion 13 is further defined by a pitch 6 of the protrusions 4. This pitch 6 is determined by the distance between the centers of two adjacent protrusions 4. The protrusion 4 is also determined by its depth 7. The depth 7 of the protrusion is equal to the thickness of the wrapper 10 without embossing plus the height of the protrusion 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.

Claims (17)

1. An aerosol-generating article for producing an inhalable aerosol upon heating, wherein the aerosol-generating article comprises: a rod of an aerosol-generating substrate, wherein the rod of an aerosol-generating substrate has an aerosol-forming substance content of at least 5 percent on a dry weight basis; and a wrapper wrapped around at least a portion of the aerosol-generating article, wherein the wrapper comprises an embossed portion surrounding at least the rod of an aerosol-generating substrate, wherein the embossed portion of the wrapper surrounds the rod of an aerosol-generating substrate along at least 80 percent of the length of the rod. 2. An aerosol-generating article according to claim 1, characterized in that the aerosol-forming substrate rod has an aerosol-forming substance content of at least 15 percent based on dry weight. 3. An aerosol-generating article according to claim 1, characterized in that the wrapper is a paper wrapper. 4. An aerosol-generating article according to any preceding claim, wherein the aerosol-forming substance has a glycerol content of at least 10 percent by weight. 5. An aerosol-generating article according to any preceding claim, wherein the embossed portion of the wrapper is a water-resistant wrapper. 6. An aerosol-generating article according to any preceding claim, wherein the embossed portion of the wrapper directly surrounds the rod of aerosol-generating substrate. 7. An aerosol-generating article according to any preceding claim, wherein the embossed portion completely surrounds the rod of aerosol-generating substrate around the circumference of the rod. 8. An aerosol-generating article according to any preceding claim, wherein the embossed portion surrounds the rod of aerosol-generating substrate along at least 90 percent of the length of the rod, more preferably along 100 percent of the length of the rod. 9. An aerosol-generating article according to any preceding claim, characterized in that the embossed portion of the wrapper has a convex outer surface and a concave inner surface. 10. An aerosol-generating article according to any preceding claim, wherein the embossed portion of the wrapper has a basis weight of from 50 grams per square meter to 100 grams per square meter, preferably from 60 grams per square meter to 90 grams per square meter, most preferably from 75 grams per square meter to 80 grams per square meter. 11. An aerosol-generating article according to any preceding claim, characterized in that the embossed portion of the wrapper has a plurality of convexities. 12. An aerosol-generating article according to any preceding claim, characterized in that 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. 13. An aerosol generating article according to any preceding claim, characterized in that the embossed portion of the wrapper has an angle memory of from 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. 14. An aerosol-generating article according to any preceding claim, wherein the aerosol-generating substrate rod comprises a gel composition. 15. An aerosol-generating article according to claim 14, wherein the gel composition comprises at least one gelling agent and at least one of an alkaloid compound and a cannabinoid compound. 16. An aerosol-generating article according to claim 14 or 15, characterized in that the gel composition contains a substance for forming an aerosol. 17. An aerosol-generating article according to any preceding claim, further comprising an elongated susceptor element extending longitudinally through the rod of aerosol-generating substrate.