RU2831259C1 - Aerosol-generating article with elongated pantograph - Google Patents

Abstract

FIELD: smoking accessories.

SUBSTANCE: disclosed is aerosol-generating article (10) comprising rod (12) of an aerosol-generating substrate and an elongated current collector (44) located longitudinally inside the aerosol-generating substrate. Current collector (44) has thickness from 55 mcm to 65 mcm.

EFFECT: technical result consists in meeting the need for aerosol-generating products that are easy to use and have high practicality and which could be made efficiently and at high speed, preferably with satisfactory resistance to draw (RTD) and low variability of RTD from one article to another.

16 cl, 2 dwg

Description

The present invention relates to an aerosol-generating article comprising an aerosol-generating substrate and configured to generate an inhalable aerosol upon heating.

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

In a number of prior art documents, aerosol-generating devices for consuming aerosol-generating articles are disclosed. Such devices include, for example, electrically heated aerosol-generating devices, in which the aerosol is generated as a result of heat transfer 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 heating blade adapted to be inserted into an aerosol-generating substrate. Alternatively, inductively heated aerosol-generating articles have been proposed in WO 2015/176898, comprising an aerosol-generating substrate and a current collector located within the aerosol-generating substrate.

Aerosol-generating articles in which the tobacco-containing substrate is heated rather than burned pose a number of problems that are not encountered in conventional smoking articles. First, the tobacco-containing substrates are typically heated to much lower temperatures than those reached by the combustion front in a conventional cigarette. This may impact the release of nicotine from the tobacco-containing substrate and the delivery of nicotine to the consumer. At the same time, if the heating temperature is increased in an attempt to enhance nicotine delivery, the generated aerosol will typically require greater and faster cooling before it reaches the consumer. However, technical solutions that have been widely used to cool the inhaled smoke stream in conventional smoking articles, such as the provision of a highly efficient filter segment at the mouth end of a cigarette, may have an undesirable effect on an aerosol-generating article in which the tobacco-containing substrate is heated rather than burned, as they may result in a decrease in nicotine delivery. Secondly, there is a general need for aerosol generating products that are easy to use and have increased practicality.

In addition, it would be desirable to provide such an aerosol generating article that could be manufactured efficiently and at high speed, preferably with satisfactory resistance to draw (RTD) and low variability in RTD from one article to another.

It would therefore be desirable to provide a new and improved aerosol generating article capable of achieving at least one of the desired results described above.

The present invention relates to an aerosol-generating article comprising a rod of an aerosol-generating substrate. The aerosol-generating article may comprise an elongated current collector located longitudinally inside the aerosol-generating substrate. The current collector may have a thickness of approximately 55 micrometers to approximately 65 micrometers.

According to the present invention, an aerosol-generating article is proposed, comprising: a rod of an aerosol-generating substrate; and an elongated current collector located longitudinally inside the aerosol-generating substrate. The current collector has a thickness of about 55 micrometers to about 65 micrometers.

Without being bound by theory, the present inventors believe that in general the selection of a given thickness for the current collector is also influenced by the limitations set by the selected length and width of the current collector, as well as the limitations set by the geometry and dimensions of the rod of the aerosol-generating substrate. For example, the length of the current collector is preferably selected so that it coincides with the length of the rod of the aerosol-generating substrate. The width of the current collector should preferably be selected so that displacement of the current collector within the substrate is prevented while ensuring the possibility of easy insertion during manufacture.

The inventors of the present invention have found that an aerosol-generating article in which a susceptor having a thickness in the range described above is provided for inductively supplying heat during use provides an advantage consisting in the possibility of particularly efficient and optimal heat generation and distribution throughout the aerosol-generating substrate. Without reference to theory, the inventors of the present invention believe that this is the case as a result of the fact that one such susceptor is designed to provide optimal heat generation and heat transfer due to the surface area of the susceptor and the inductive power. In contrast, a thinner susceptor may deform too easily and it may not maintain the required shape and orientation within the rod of the aerosol-generating substrate during the manufacturing process of the aerosol-generating article, which may lead to a less uniform and less accurately controlled heat distribution during use. At the same time, a thicker susceptor may create difficulties in terms of its precise and reproducible cutting to the desired length, and this may also affect the accuracy of the longitudinal alignment of the susceptor within the rod of the aerosol-generating substrate, which also potentially affects the uniformity of the heat distribution within the rod. These advantageous effects are particularly noticeable when the susceptor extends the entire distance to the downstream end of the rod of the aerosol-generating article. It is believed that this is due to the possibility of generally reducing the resistance to draw (RTD) downstream of the susceptor due to the absence of an aerosol-generating substrate capable of contributing to the RTD within the rod at a location downstream of the susceptor. This is particularly effectively achieved in some preferred embodiments, which will be described in more detail below and in which the aerosol-generating article comprises a downstream section comprising a hollow intermediate section. One such hollow intermediate section does not substantially contribute to the overall RTD of the aerosol generating article and does not come into direct contact with the downstream end of the susceptor.

Without being bound by theory, the present inventors believe that the furthest downstream portion of the aerosol-generating substrate rod may act to some extent as a filter with respect to the upstream portions of the aerosol-generating substrate rod. Accordingly, the present inventors believe that it is desirable to be able to uniformly heat also the furthest downstream portion of the aerosol-generating substrate rod to actively involve it in the release of the volatile compounds of the aerosol and to assist in the overall generation and delivery of the aerosol, and any possible filtering effect that may interfere with the delivery of the aerosol to the consumer is reliably eliminated by the release of the volatile compounds of the aerosol throughout the aerosol-generating substrate.

According to the present invention, an aerosol-generating article is proposed for generating an inhalable aerosol upon heating. The aerosol-generating article comprises a rod of an aerosol-generating substrate.

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

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

As used herein, the term "aerosol generating device" refers to a device comprising a heating element that interacts with an aerosol generating substrate of an aerosol generating article to generate an aerosol.

As used herein in connection with the present invention, the term "rod" is used to describe a substantially cylindrical member with a substantially circular, oval, or elliptical cross-section.

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

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

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

The aerosol-generating substrate may be a solid aerosol-generating substrate.

In some preferred embodiments, the aerosol generating substrate comprises homogenized plant material, preferably homogenized tobacco material.

As used herein, the term "homogenized plant material" encompasses any plant material obtained by agglomerating plant particles. For example, sheets or webs of homogenized tobacco material for aerosol-generating substrates according to the present invention can be formed by agglomerating tobacco material particles obtained by grinding, milling or grinding the plant material and, optionally, one or more of tobacco leaf blades and tobacco leaf veins. The homogenized plant material can be obtained by casting, extrusion, papermaking or any other suitable processes known in the art.

The homogenized plant material may be provided in any suitable form. For example, the homogenized plant material may be present in the form of one or more sheets. As used herein in connection with the present invention, the term "sheet" describes a flat element whose width and length substantially exceed its thickness.

Alternatively or additionally, the homogenized plant material may be present in the form of a plurality of beads or granules.

Alternatively or additionally, the homogenized plant material may be present in the form of a plurality of strands, strips or pieces. As used herein, the term "strand" describes an elongated element of material whose length substantially exceeds its width and thickness. The term "strand" should be considered to include strips, pieces and any other homogenized plant material having a similar shape. The strands of homogenized plant material may be obtained from a sheet of homogenized plant material, for example, by cutting or shredding or by other means, for example, by extrusion.

In some embodiments, the threads may be produced directly in situ within the aerosol-generating substrate by dividing or splitting a sheet of homogenized plant material during the formation of the aerosol-generating substrate, for example, as a result of corrugation. The threads of homogenized plant material within the aerosol-generating substrate may be separated from each other. Alternatively, each thread of homogenized plant material within the aerosol-generating substrate may be at least partially connected to an adjacent thread or threads along the length of the threads. For example, adjacent threads may be connected by one or more fibers. This may be the case, for example, if the threads were produced by dividing a sheet of homogenized plant material during the production of the aerosol-generating substrate, as described above.

Preferably, the aerosol-generating substrate is present in the form of one or more sheets of homogenized plant material. In various embodiments of the present invention, said one or more sheets of homogenized plant material can be made by a casting process. In various embodiments of the present invention, said one or more sheets of homogenized plant material can be made by a papermaking process. Each of said one or more sheets described herein can have an individual thickness of about 100 micrometers to 600 micrometers, preferably from 150 micrometers to 300 micrometers, most preferably from 200 micrometers to 250 micrometers. Individual thickness refers to the thickness of an individual sheet, while the cumulative thickness refers to the total thickness of all sheets that form the aerosol-generating substrate. For example, if the aerosol generating substrate is formed from two separate sheets, then the combined thickness is the sum of the thicknesses of the two separate sheets or the measured thickness of the two sheets when the two sheets are stacked on top of each other in the aerosol generating substrate.

Each of the one or more sheets described herein may have an individual grammage of from about 100 grams per square meter to about 300 grams per square meter.

Each of the one or more sheets described herein may have an individual density of from about 0.3 grams per cubic centimeter to about 1.3 grams per cubic centimeter, preferably from about 0.7 grams per cubic centimeter to about 1.0 grams per cubic centimeter.

In those embodiments of the present invention in which the aerosol-generating substrate comprises one or more sheets of homogenized plant material, these sheets are preferably present in the form of one or more assembled sheets. The term "assembled" as used herein is used to describe a sheet of homogenized plant material that is rolled, bent, or otherwise compressed or narrowed in a direction substantially transverse to the cylindrical axis of the plug or rod.

Said one or more sheets of homogenized plant material may be collected transversely relative to its longitudinal axis and surrounded by a wrapper to form a continuous rod or plug.

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

Preferably, each sheet of homogenized plant material may be corrugated so that it has a plurality of folds or corrugations substantially parallel to the cylindrical axis of the plug. This treatment provides the advantage of facilitating the corrugation of the sheet of homogenized plant material to form the plug. Preferably, said one or more sheets of homogenized plant material may be collected. It should be understood that the corrugated sheets of homogenized plant material may alternatively or additionally have a plurality of substantially parallel folds or corrugations located at an acute or obtuse angle to the cylindrical axis of the plug. The sheet may be corrugated to such an extent that the integrity of the sheet is broken at the plurality of parallel folds or corrugations, which leads to separation of the material and the formation of pieces, threads or strips of homogenized plant material.

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

Said plurality of threads preferably extend substantially in the longitudinal direction along the length of the aerosol-generating substrate and are aligned with the longitudinal axis. Accordingly, said plurality of threads are preferably aligned substantially parallel to each other.

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

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

In some embodiments of the present invention, the homogenized plant material is a homogenized tobacco material comprising tobacco particles. Sheets of homogenized tobacco material for use in such embodiments of the present invention may have a tobacco content of at least about 40 percent by weight on a dry weight basis, more preferably at least about 50 percent by weight on a dry weight basis, more preferably at least about 70 percent by weight on a dry weight basis, and most preferably at least about 90 percent by weight on a dry weight basis.

As used herein, the term "tobacco particles" describes particles of any plant belonging to the genus Nicotiana. The term "tobacco particles" includes ground or powdered tobacco leaf blades, ground or powdered tobacco leaf stalks, tobacco dust, tobacco fines, and other particulate tobacco by-products generated during the processing, handling, and shipping of tobacco. In a preferred embodiment, substantially all of the tobacco particles are derived from tobacco leaf blades. In contrast, pure nicotine and nicotine salts are compounds derived from tobacco but are not considered tobacco particles for the purposes of this invention and are not included in the percentage of particulate plant material.

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

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

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

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

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

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

In some other embodiments of the present invention, the homogenized plant material comprises tobacco particles in combination with non-tobacco plant flavor particles. Preferably, the non-tobacco plant flavor particles are selected from one or more of the following: ginger particles, eucalyptus particles, clove particles, and star anise particles. Preferably, in such embodiments, the homogenized plant material comprises at least about 2.5 percent by weight of non-tobacco plant flavor particles on a dry weight basis, with the remainder of the plant particles being tobacco particles. Preferably, the homogenized plant material comprises at least about 4 percent by weight of non-tobacco botanical flavor particles, more preferably at least about 6 percent by weight of non-tobacco botanical flavor particles, more preferably at least about 8 percent by weight of non-tobacco botanical flavor particles, more preferably at least about 10 percent by weight of non-tobacco botanical flavor particles, based on dry weight. Preferably, the homogenized plant material comprises up to about 20 percent by weight of non-tobacco botanical flavor particles, more preferably up to about 18 percent by weight of non-tobacco botanical flavor particles, more preferably up to about 16 percent by weight of non-tobacco botanical flavor particles.

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

Alternatively or additionally to the inclusion of tobacco particles in the homogenized plant material of the aerosol generating substrate according to the present invention, the homogenized plant material may comprise hemp particles. The term "hemp particles" refers to particles of the hemp plant, such as the species Cannabis sativa, Cannabis indica and Cannabis ruderalis.

The homogenized plant material preferably comprises no more than 95 percent by weight of particulate plant material on a dry weight basis. Thus, the particulate plant material is typically mixed with one or more other components to produce the homogenized plant material.

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

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

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

Alternatively or additionally, the homogenized plant material may further comprise a pH modifier.

Alternatively or additionally, the homogenized plant material may further comprise fibers for altering the mechanical properties of the homogenized plant material, said fibers being incorporated into the homogenized plant material during manufacture as described herein. Suitable exogenous fibers for inclusion in the homogenized plant material are known in the art and include fibers derived from material other than tobacco and material other than ginger, including, but not limited to: cellulose fibers; softwood fibers; hardwood fibers; jute fibers, and combinations thereof. Exogenous fibers derived from tobacco and/or ginger may also be added. Any fibers added to the homogenized plant material are not considered to form part of the "particulate plant material" defined above. Prior to incorporation into the homogenized plant material, the fibers may be processed by suitable methods known in the art, including, but not limited to: mechanical pulping; cleaning; chemical pulping; bleaching; sulphate pulping; and combinations thereof. The fibre is usually longer than it is wide.

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

Alternatively or additionally, the homogenized plant material may further comprise one or more aerosol formers. Upon evaporation, the aerosol former is capable of transporting other volatile compounds released from the aerosol-generating substrate upon heating, such as nicotine and flavoring agents, into the aerosol. Aerosol formers suitable for inclusion in the homogenized plant material 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 homogenized plant material may have an aerosol forming agent 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, then it may preferably have an aerosol-forming substance content of from about 5 percent to about 30 percent by weight on a dry weight basis. If the substrate is intended for use in an aerosol-generating article for an electric aerosol-generating system having a heating element, then the aerosol-forming substance is preferably glycerol.

In other embodiments, the homogenized plant material 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 entrain flavor substances from the aerosol-generating substrate into the aerosol.

In other embodiments, the homogenized plant material may have an aerosol former content of from about 30 percent by weight to about 45 percent by weight. This relatively high level of aerosol former is particularly suitable for aerosol-generating substrates that are intended to be heated at a temperature of less than 275 degrees Celsius. In such embodiments, the homogenized plant material 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 former content of from 30 percent by weight to 45 percent by weight.

Suitable cellulose ethers include, but are not limited to, methylcellulose, hydroxypropylmethylcellulose, ethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, ethylhydroxyethylcellulose, and carboxymethylcellulose (CMC). In particularly preferred embodiments, the cellulose ether is carboxymethylcellulose.

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

Additional cellulose may include cellulose powder, cellulose fibers, or a combination of both.

The aerosol forming agent can act as a humectant in the aerosol generating substrate.

The wrapper surrounding the rod of homogenized plant material may be a paper wrapper or a non-paper wrapper. Paper wrappers suitable for use in particular embodiments of the present invention are known in the art and include, but are not limited to: cigarette papers; and filter wicks. Suitable non-paper wrappers for use in particular embodiments of the present invention are known in the art and include, but are not limited to, sheets of homogenized tobacco materials. In some preferred embodiments, the wrapper may be made of a laminate containing a plurality of layers. Preferably, the wrapper is made of a laminated sheet with aluminum. The use of a laminated sheet containing aluminum provides the advantage of preventing combustion of the aerosol-generating substrate in the event that the aerosol-generating substrate is ignited rather than properly heated.

In some preferred embodiments of the present invention, the aerosol-generating substrate comprises a gel composition that includes an alkaloid compound or a cannabinoid compound, or both an alkaloid compound and a cannabinoid compound. In particularly preferred embodiments, the aerosol-generating substrate comprises a gel composition that includes nicotine.

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, said at least one gelling agent forms a solid medium, and glycerol is distributed in this solid medium, and the alkaloid or cannabinoid is distributed in glycerol. Preferably, the gel composition is a stable gel phase.

As an advantage, the stable gel-like composition containing nicotine provides a predictable shape of the composition during storage or transportation from production to the consumer. The stable gel-like composition containing nicotine essentially retains its shape. The stable gel-like composition containing nicotine essentially does not release a liquid phase during storage or transportation from production to the consumer. The stable gel-like composition containing nicotine provides the possibility of creating a simple design of the consumable part. This consumable part can be made without necessarily containing liquid in it, and thus the possibility of using a wider range of materials and designs in the container is provided.

The gel composition described herein may be combined with an aerosol generating device for delivering nicotine aerosol to the lungs at inhalation or air flow rates that do not exceed inhalation or air flow rates in a typical smoking mode. The aerosol generating device may continuously heat the gel composition. The consumer may take multiple inhalations or "puffs," with each "puff" delivering a certain amount of nicotine aerosol. The gel composition may be capable of delivering a high nicotine/low total particulate matter (TPM) aerosol to the consumer upon heating, preferably in a continuous manner.

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

The gel composition includes an alkaloid compound or a cannabinoid compound, or both an alkaloid compound and a cannabinoid compound. The gel composition may include one or more alkaloids. The gel composition may include one or more cannabinoids. The gel composition may include 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 nitrogenous base atoms. Typically, an alkaloid includes 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 especially common in certain families of flowering plants. However, some alkaloid compounds are found in animal and fungal species. In the present disclosure, the term "alkaloid compound" refers to both naturally occurring alkaloid compounds and synthetically produced alkaloid compounds.

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

Preferably, the gel composition comprises nicotine.

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

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

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

The gel may preferably contain cannabidiol (CBD).

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

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

The gel composition preferably comprises from about 0.5 percent by weight to about 10 percent by weight of an alkaloid compound, or from about 0.5 percent by weight to about 10 percent by weight of a cannabinoid compound, or both of the alkaloid compound and the cannabinoid compound in a total amount of from about 0.5 percent by weight to about 10 percent by weight. The gel composition can comprise from about 0.5 percent by weight to about 5 percent by weight of an alkaloid compound, or from about 0.5 percent by weight to about 5 percent by weight of a cannabinoid compound, or both of the alkaloid compound and the cannabinoid compound in a total amount of from about 0.5 percent by weight to about 5 percent by weight. Preferably, the gel composition comprises from about 1 percent by weight to about 3 percent by weight of an alkaloid compound, or from about 1 percent by weight to about 3 percent by weight of a cannabinoid compound, or both of the alkaloid compound and the cannabinoid compound in a total amount of from about 1 percent by weight to about 3 percent by weight. The gel composition may preferably contain from about 1.5 percent by weight to about 2.5 percent by weight of an alkaloid compound, or from about 1.5 percent by weight to about 2.5 percent by weight of a cannabinoid compound, or both of the alkaloid compound and the cannabinoid compound in a total amount of from about 1.5 percent by weight to about 2.5 percent by weight. The gel composition may preferably include about 2 percent by weight of an alkaloid compound, or about 2 percent by weight of a cannabinoid compound, or both of the alkaloid compound and the cannabinoid compound in a total amount of about 2 percent by weight. The component of the gel composition that is an alkaloid compound may be the most volatile component of the gel composition. In some aspects, water may be the most volatile component of the gel composition, and the component of the gel composition that is an alkaloid compound may be the second most volatile component of the gel composition. The component of the gel composition that is a cannabinoid compound may be the most volatile component of the gel composition. In some aspects, water may be the most volatile component of the gel composition, and the component of the gel composition that is an alkaloid compound may be the second most volatile component of the gel composition.

Preferably, nicotine is included in the gel compositions. Nicotine can be added to the composition as a free base or as a salt. The gel composition includes from about 0.5 percent by weight to about 10 percent by weight nicotine, or from about 0.5 percent by weight to about 5 percent by weight nicotine. Preferably, the gel composition includes from about 1 percent by weight to about 3 percent by weight nicotine, or from about 1.5 percent by weight to about 2.5 percent by weight nicotine, or about 2 percent by weight nicotine. The nicotine component of the gel composition can be the most volatile component of the gel composition. In some aspects, water can be the most volatile component of the gel composition, and the nicotine component of the gel composition can be the second most volatile component of the gel composition.

The gel composition includes an aerosol former. Ideally, the aerosol former is substantially resistant to thermal degradation at the operating temperature of the corresponding 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 include a major part of an aerosol forming agent. The gel composition may include a mixture of water and an aerosol forming agent, wherein the aerosol forming agent forms a major part (by weight) of the gel composition. The aerosol forming agent may form at least about 50 percent by weight of the gel composition. Said aerosol forming agent may form at least about 60 percent by weight, or at least about 65 percent by weight, or at least about 70 percent by weight of the gel 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 include a major portion of glycerol. The gel composition may include a mixture of water and glycerol, wherein glycerol forms a major portion (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 preferably comprises at least one gelling agent. Preferably, the total amount of gelling agents in the gel composition is in the range of about 0.4 percent by weight to about 10 percent by weight. More preferably, the amount of gelling agents in said composition is in the range of about 0.5 percent by weight to about 8 percent by weight. More preferably, the amount of gelling agents in said composition is in the range of about 1 percent by weight to about 6 percent by weight. More preferably, the amount of gelling agents in said composition is in the range of about 2 percent by weight to about 4 percent by weight. More preferably, the amount of gelling agents in said composition is in the range of about 2 percent by weight to about 3 percent by weight.

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

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

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

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

The term "hydrogen bonding crosslinking gelling agent" refers to a gelling agent that forms non-covalent crosslinking bonds or physical crosslinking bonds through hydrogen bonding. Hydrogen bonding is a type of electrostatic dipole-dipole attraction between molecules rather than a covalent bond with a hydrogen atom. It is caused by the 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 crosslinking by means of hydrogen bonds may comprise one or more of galactomannan, gelatin, agarose or konjac gum, or agar. The gelling agent providing crosslinking by means of hydrogen bonds may preferably comprise agar.

Said gel composition preferably comprises a gelling agent providing crosslinking via hydrogen bonds in a range from about 0.3 percent by weight to about 5 percent by weight. Preferably, the composition comprises a gelling agent providing crosslinking via hydrogen bonds in a range from about 0.5 percent by weight to about 3 percent by weight. Preferably, the composition comprises a gelling agent providing crosslinking via hydrogen bonds in a range from about 1 percent by weight to about 2 percent by weight.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

The gel composition may further comprise a viscosity enhancing agent. Surprisingly, the viscosity enhancing agent, in combination with a gelling agent providing crosslinking by hydrogen bonds and a gelling agent providing crosslinking by ionic bonds, maintains a solid environment and preserves the gel composition, even when the gel composition includes a high level of glycerol.

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

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

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

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

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

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

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

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

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

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

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

The gel composition may include starch in a range of about 0.2 percent by weight to about 5 percent by weight. Preferably, the starch may be present in a range of about 0.5 percent by weight to about 3 percent by weight. Preferably, the starch may be present in a range of about 0.5 percent by weight to about 2 percent by weight. Preferably, the starch may be present in a range of about 1 percent by weight to about 2 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) are capable of promoting gelation of compositions that comprise gelling agents, such as, for example, a gelling agent that provides crosslinking through ionic bonds. The ionic effect may promote gelation. The divalent cation may be present in the gel composition in a range of about 0.1 to about 1 percent by weight, or in an amount of about 0.5 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 may comprise a ketone group having less than about 10 carbon atoms, or less than about 6 carbon atoms, or less than about 4 carbon atoms, such as levulinic acid or lactic acid. Preferably, this carboxylic acid has three carbon atoms (e.g., lactic acid). Surprisingly, lactic acid improves the stability of the gel composition even compared to similar carboxylic acids. The carboxylic acid is capable of promoting gel formation. The carboxylic acid may reduce the change in the concentration of the alkaloid compound or the concentration of the cannabinoid compound, or both the concentration of the alkaloid compound and the cannabinoid compound in the gel composition during storage. The said carboxylic acid is capable of reducing the change in the concentration of nicotine in the gel composition during storage.

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

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

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

The gel composition preferably contains some amount of water. The gel composition is more stable when 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 comprises from about 150 mg to about 350 mg of the gel composition.

Preferably, the aerosol-generating substrate comprises a porous medium loaded with a gel-like composition. The advantage of a porous medium loaded with a gel-like composition is that the gel-like composition is retained within the porous medium, and this provides the possibility of facilitating the manufacture, storage or transportation of the gel-like composition. This provides the possibility of facilitating the maintenance of the desired shape of the gel-like composition, especially during manufacture, transportation or use.

The porous medium may be any suitable porous material capable of storing or retaining the gel composition. Ideally, the porous medium is capable of allowing the gel composition to move within it. In particular embodiments, the porous medium comprises natural materials, synthetic materials or semi-synthetic materials, or a combination thereof. In particular embodiments, the porous medium comprises a sheet material, a foam material or fibers, such as loose fibers, or a combination thereof. In particular embodiments, the porous medium comprises 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. In a particularly preferred embodiment, the porous medium comprises a sheet made of cotton fibers.

The porous medium used in the present invention may be corrugated or ground. In preferred embodiments, the porous medium is corrugated. In alternative embodiments, the porous medium comprises ground porous medium. The corrugation or grinding process may be performed before or after loading the gel composition.

Corrugation of the sheet material provides the advantage of improving the structure to provide passages through the structure. The passages through the corrugated sheet material facilitate filling with gel, retaining the gel, and also the passage of fluid through the corrugated sheet material. Thus, advantages are provided when using the corrugated sheet material as a porous medium.

Milling provides a high surface area to volume ratio of the medium, which is thus able to easily absorb the gel.

In particular embodiments, the sheet material is a composite material. Preferably, the sheet material is porous. The sheet material provides the ability to facilitate the production of a tubular element containing a gel. The sheet material provides the ability to facilitate the introduction of an active substance into a tubular element containing a gel. The sheet material provides the ability to facilitate the stabilization of the structure of the tubular element containing a gel. The sheet material provides the ability to facilitate the transportation or storage of the gel. The use of the sheet material provides the ability to impart structure to a porous medium or facilitates this, for example, by corrugating the sheet material.

The porous medium may be a thread. The thread may contain, for example, cotton, paper or acetate tow. The thread may also be loaded with a gel, similar to any other porous medium. The advantage of using a thread as a porous medium is that it provides the ability to facilitate ease of manufacture.

The thread may be loaded with gel by any known means. The thread may simply be coated with gel, or the thread may be impregnated with gel. During manufacture, the threads may be impregnated with gel and stored ready for use in the tubular assembly process.

The porous medium loaded with the gel composition is preferably provided within a tubular element that forms part of the aerosol-generating article. The term "tubular element" is used to describe a component suitable for use in an aerosol-generating article. Ideally, the tubular element may be longer in longitudinal length than in width, but this is not necessary, since it may be part of a multi-component element that will ideally be longer in its longitudinal length than in its width. Typically, the tubular element is cylindrical, but this is not necessary. For example, the tubular element may have an oval, polygonal, such as triangular or rectangular, or an arbitrary cross-section.

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

Preferably, in those embodiments in which the rod of the aerosol-generating substrate comprises a gel composition as described above, the downstream section of the aerosol-generating article comprises an aerosol cooling element having a length of less than 10 millimeters. It has been found that the use of a relatively short aerosol cooling element in combination with a gel composition optimizes the delivery of the aerosol to the consumer. Further details regarding the aerosol cooling elements will be described below.

Those embodiments of the present invention in which the rod of the aerosol-generating substrate comprises a gel composition as described above preferably comprise an upstream element located upstream of the rod of the aerosol-generating substrate. In this case, the upstream element advantageously prevents physical contact with the gel composition. The upstream element may also advantageously compensate for any potential decrease in RTD, for example due to evaporation of the gel composition when the rod of the aerosol-generating substrate is heated during use. Further details regarding the provision of one such upstream element will be described below.

As briefly described above, the aerosol generating article according to the present invention comprises an elongated current collector located substantially longitudinally within the rod of the aerosol generating substrate.

As used herein in connection with the present invention, the term "susceptor" refers to a material that is capable of converting electromagnetic energy into heat. When placed within a fluctuating electromagnetic field, eddy currents induced in the susceptor cause the susceptor to heat up. Since the elongated susceptor is placed in thermal contact with an aerosol-generating substrate, the aerosol-generating substrate is heated by the susceptor.

When used to describe a current collector, the term "extended" means that the current collector has a length dimension that is greater than its width dimension or its thickness dimension, such as twice its width dimension or its thickness dimension.

The current collector is located substantially longitudinally within the rod. This means that the lengthwise dimension of the elongated current collector runs approximately parallel to the longitudinal direction of the rod, for example parallel to the longitudinal direction of the rod with a deviation of plus or minus 10 degrees. In preferred embodiments, the elongated current collector may be located centrally in the radial direction within the rod and runs along the longitudinal axis of the rod.

Preferably, the current collector extends the entire distance to the downstream end of the rod of the aerosol-generating article. In some embodiments, the current collector may extend the entire distance to the upstream end of the rod of the aerosol-generating article. In particularly preferred embodiments, the current collector has substantially the same length as the rod of the aerosol-generating substrate, and it extends from the upstream end of the rod to the downstream end of the rod.

The current collector is preferably made in the form of a pin, rod, strip or blade.

The current collector preferably has 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 collector and the overall length of the aerosol generating article may be from about 0.2 to about 0.35.

Preferably, the ratio between the length of the current collector and the total length 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 collector and the total length 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.

In some embodiments, the ratio between the length of the susceptor and the overall length 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. In other embodiments, the ratio between the length of the susceptor and the overall length 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. In further embodiments, the ratio between the length of the susceptor and the overall length 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.

In a particularly preferred embodiment, the ratio between the length of the current collector and the total length of the aerosol generating article is approximately 0.27.

The current collector preferably has a thickness of from about 57 micrometers to about 63 micrometers, more preferably from about 58 micrometers to about 62 micrometers.

Preferably, the current collector has a width of at least about 1 millimeter, more preferably at least about 2 millimeters. Typically, the current collector may have a width of up to 8 millimeters, preferably less than 6 millimeters or equal to about 6 millimeters.

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

If the current collector has the form of a strip or blade, then this strip or blade preferably has a rectangular shape with a width of preferably from about 2 millimeters to about 8 millimeters, more preferably from about 3 millimeters to about 6 millimeters. For example, a current collector in the form of a strip or blade can have a width of about 4 millimeters.

In a preferred embodiment, the elongated current collector is in the form of a strip or blade, has a substantially rectangular shape, and its thickness is from about 55 micrometers to about 65 micrometers. More preferably, the elongated current collector has a thickness of from about 57 micrometers to about 63 micrometers. Even more preferably, the elongated current collector has a thickness of from about 58 micrometers to about 62 micrometers. In a particularly preferred embodiment, the elongated current collector has a thickness of about 60 micrometers.

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

The current collector may be made of any material that is capable of being inductively heated to a temperature sufficient to generate an aerosol from an aerosol-generating substrate. Preferred current collectors comprise metal or carbon.

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

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

Suitable current collectors 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 collector may have a protective outer layer, for example a protective ceramic layer or a protective glass layer, enclosing the current collector. The current collector may comprise a protective coating made of glass, ceramic or inert metal over a core of current collector material.

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

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

By providing a current collector having at least a first and a second current collector material, wherein either the second current collector material has a Curie temperature and the first current collector material does not have a Curie temperature, or the first and second current collector 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 regulate the heating temperature. The first current collector material is preferably a magnetic material having a Curie temperature above 500 degrees Celsius. From the viewpoint of heating efficiency, it is desirable that the Curie temperature of the first current collector material exceeds any maximum temperature to which the current collector is capable of heating. The second Curie temperature can be preferably selected so that it is below 400 degrees Celsius, preferably below 380 degrees Celsius or below 360 degrees Celsius. Preferably, the second current-collecting material is a magnetic material selected in such a way that it has a second Curie temperature that substantially coincides with the desired maximum heating temperature. In other words, it is preferable that the second Curie temperature is approximately the same as the temperature to which the current collector must be heated in order to generate an aerosol from the aerosol-generating substrate. The second Curie temperature can be, for example, within the range from 200 degrees Celsius to 400 degrees Celsius or from 250 degrees Celsius to 360 degrees Celsius. The second Curie temperature of the second current-collecting material can be selected, for example, such that when heated by means of the current collector, which is at a temperature equal to the second Curie temperature, the overall average temperature of the aerosol-generating substrate does not exceed 240 degrees Celsius.

Preferably, the aerosol generating article further comprises a downstream section at a location downstream of the aerosol generating substrate rod. The downstream section may comprise one or more downstream elements.

The downstream section of the aerosol-generating articles according to the present invention preferably comprises an intermediate hollow section comprising an aerosol cooling element arranged in alignment with the rod of the aerosol-generating substrate, downstream relative to it. In some embodiments, the intermediate hollow section may further comprise a support element arranged downstream relative to the rod of the aerosol-generating substrate immediately after it, and the aerosol cooling element may be located between the support element and the downstream end (or mouth end) of the aerosol-generating article. More particularly, the aerosol cooling element may be arranged downstream relative to the support element immediately after it. In some embodiments, the aerosol cooling element may be adjacent to the support element. As will be described below, the downstream section may further comprise one or more additional elements arranged downstream relative to the intermediate hollow section.

In some embodiments, the aerosol cooling element is present in the form of a hollow tubular segment that forms a cavity extending the entire distance from the upstream end of the aerosol cooling element to the downstream end of the aerosol cooling element, and a ventilation zone is provided at a location along the hollow tubular segment.

As used herein, the term "hollow tubular segment" is used to designate a substantially elongated element that defines a lumen or passage for air flow along its longitudinal axis. In particular, the term "tubular" will be used hereinafter to refer to a tubular element that has a substantially cylindrical cross-section and defines at least one air flow channel that provides 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 geometries (e.g., alternative cross-sectional shapes) of the tubular element are possible.

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

When used to describe an aerosol cooling element, the term "elongated" means that the aerosol cooling element has a length dimension greater than its width dimension or its diameter dimension, such as two or more times its width dimension or its diameter dimension.

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

Without reference to theory, it is believed that since the temperature of the aerosol stream is rapidly reduced by introducing ventilation air as the aerosol passes toward the mouthpiece segment, with the ventilation air entering the aerosol stream at a location relatively close to the upstream end of the aerosol cooling element (i.e., sufficiently close to the current collector that extends inside the rod of the aerosol-generating substrate and is a source of heat during use), a sharp cooling of the aerosol stream is achieved, which has a favorable effect on the condensation and nucleation of aerosol particles. Accordingly, it is possible to improve the overall ratio of the particulate aerosol phase to the gas phase of the aerosol compared to existing non-ventilated aerosol-generating articles.

At the same time, by maintaining a relatively small thickness of the peripheral wall of the hollow tubular element, it is ensured that the total internal volume of the hollow tubular element, which becomes available for the aerosol nucleation process to begin immediately after the aerosol components leave the rod of the aerosol-generating substrate, and the cross-sectional area of the hollow tubular segment are effectively maximized, while ensuring that the hollow tubular segment has sufficient structural strength to prevent the aerosol-generating article from collapsing, as well as providing some support for the rod of the aerosol-generating substrate and minimizing the RTD of the hollow tubular segment. It is understood that increased values of the cross-sectional area of the cavity of the hollow tubular segment are associated with a decrease in the flow rate of the aerosol moving along the aerosol-generating article, which is also expected to promote aerosol nucleation. In addition, it is assumed that by using a hollow tubular segment having a comparatively small thickness, it is possible to essentially prevent the diffusion of ventilation air before it comes into contact and mixes with the aerosol flow, and it is also understood that this additionally promotes nucleation phenomena. In practice, by providing more controlled localized cooling of the flow of evaporating compounds, it is possible to enhance the effect of cooling on the formation of new aerosol particles.

The aerosol cooling element is arranged substantially in alignment with the rod. This means that the length dimension of the aerosol cooling element runs approximately parallel to the longitudinal direction of the rod and the article, for example parallel to the longitudinal direction of the rod with a deviation of plus or minus 10 degrees. In preferred embodiments, the aerosol cooling element runs along the longitudinal axis of the rod.

The aerosol cooling element preferably has an outer diameter that is approximately equal to the outer diameter of the aerosol-generating substrate rod and the outer diameter of the aerosol-generating article.

The aerosol cooling element may have an outside diameter of 5 millimeters to 12 millimeters, such as 5 millimeters to 10 millimeters or 6 millimeters to 8 millimeters. In a preferred embodiment, the aerosol cooling element has an outside diameter of 7.2 millimeters plus or minus 10 percent.

Preferably, the hollow tubular segment of the aerosol cooling element has an internal diameter of at least about 2 millimeters. More preferably, the hollow tubular segment of the aerosol cooling element has an internal diameter of at least about 2.5 millimeters. Even more preferably, the hollow tubular segment of the aerosol cooling element has an internal diameter of at least about 3 millimeters.

The peripheral wall of the aerosol cooling element may have a thickness of less than about 2.5 millimeters, preferably less than 1.5 millimeters, more preferably less than about 1250 micrometers, even more preferably less than about 1000 micrometers. In particularly preferred embodiments, the peripheral wall of the aerosol cooling element has a thickness of less than about 900 micrometers, preferably less than about 800 micrometers.

In one embodiment, the peripheral wall of the aerosol cooling element has a thickness of approximately 2 millimeters.

The aerosol cooling element can have a length from 5 millimeters to 15 millimeters.

Preferably, the aerosol cooling element has a length of at least about 6 millimeters, more preferably at least about 7 millimeters.

In preferred embodiments, the aerosol cooling element has a length of less than about 12 millimeters, more preferably less than about 10 millimeters.

In some embodiments, the aerosol cooling element has a length of about 5 millimeters to about 15 millimeters, preferably about 6 millimeters to about 15 millimeters, more preferably about 7 millimeters to about 15 millimeters. In other embodiments, the aerosol cooling element has a length of about 5 millimeters to about 12 millimeters, preferably about 6 millimeters to about 12 millimeters, more preferably about 7 millimeters to about 12 millimeters. In preferred embodiments, the aerosol cooling element has a length of about 5 millimeters to about 10 millimeters, preferably about 6 millimeters to about 10 millimeters, more preferably about 7 millimeters to about 10 millimeters.

In particularly preferred embodiments, the aerosol cooling element has a length of less than 10 millimeters. For example, in one particularly preferred embodiment, the aerosol cooling element has a length of 8 millimeters. Therefore, in such embodiments, the aerosol cooling element has a relatively short length compared to aerosol cooling elements in aerosol-generating articles of the prior art. The reduction in the length of the aerosol cooling element is possible due to the optimized efficiency of the hollow tubular segment forming the aerosol cooling element in cooling and nucleating the aerosol. The reduction in the length of the aerosol cooling element advantageously reduces the risk of deformation of the aerosol-generating article due to compression during use, since the aerosol cooling element typically has a lower resistance to deformation than the mouthpiece. In addition, the reduction in the length of the aerosol cooling element is able to ensure a low cost price for the manufacturer, since the cost of the hollow tubular segment per unit length is typically higher than the cost of other elements, such as the mouthpiece element.

The ratio between the length of the aerosol cooling element and the length of the aerosol generating substrate rod may be from about 0.25 to about 1.

Preferably, the ratio between the length of the aerosol cooling element and the length of the rod of the aerosol generating substrate is at least about 0.3, more preferably at least about 0.4, even more preferably at least about 0.5. In preferred embodiments, the ratio between the length of the aerosol cooling element and the length of the rod of the aerosol generating substrate is less than about 0.9, more preferably less than about 0.8, even more preferably less than about 0.7.

In some embodiments, the ratio between the length of the aerosol cooling element and the length of the rod of the aerosol-generating substrate is from about 0.3 to about 0.9, preferably from about 0.4 to about 0.9, more preferably from about 0.5 to about 0.9. In other embodiments, the ratio between the length of the aerosol cooling element and the length of the rod of the aerosol-generating substrate is from about 0.3 to about 0.8, preferably from about 0.4 to about 0.8, more preferably from about 0.5 to about 0.8. In further embodiments, the ratio between the length of the aerosol cooling element and the length of the rod of the aerosol-generating substrate is from about 0.3 to about 0.7, preferably from about 0.4 to about 0.7, more preferably from about 0.5 to about 0.7.

In particularly preferred embodiments, the ratio between the length of the aerosol cooling element and the length of the aerosol generating substrate rod is approximately 0.66.

The ratio between the length of the aerosol cooling element and the overall length of the aerosol generating article may be from about 0.125 to about 0.375.

Preferably, the ratio between the length of the aerosol cooling element and the total length of the aerosol-generating article is at least about 0.13, more preferably at least about 0.14, even more preferably at least about 0.15. The ratio between the length of the aerosol cooling element and the total length of the aerosol-generating article is preferably less than about 0.3, more preferably less than about 0.25, even more preferably less than about 0.20.

In some embodiments, the ratio between the length of the aerosol cooling element and the overall length of the aerosol-generating article is preferably from about 0.13 to about 0.3, more preferably from about 0.14 to about 0.3, even more preferably from about 0.15 to about 0.3. In other embodiments, the ratio between the length of the aerosol cooling element and the overall length of the aerosol-generating article is preferably from about 0.13 to about 0.25, more preferably from about 0.14 to about 0.25, even more preferably from about 0.15 to about 0.25. In further embodiments, the ratio between the length of the aerosol cooling element and the overall length of the aerosol-generating article is preferably from about 0.13 to about 0.2, more preferably from about 0.14 to about 0.2, even more preferably from about 0.15 to about 0.2.

In a particularly preferred embodiment, the ratio between the length of the aerosol cooling element and the overall length of the aerosol generating article is approximately 0.18.

Preferably, the length of the mouthpiece element is at least 1 millimeter longer than the length of the aerosol cooling element, more preferably at least 2 millimeters longer than the length of the aerosol cooling element, more preferably at least 3 millimeters longer than the length of the aerosol cooling element. Reducing the length of the aerosol cooling element as described above may advantageously provide for an increase in the length of other elements of the aerosol-generating article, such as the mouthpiece element. Potential technical benefits from providing a relatively long mouthpiece element are described above.

Preferably, in the aerosol-generating articles according to the present invention, the aerosol cooling element has an average radial hardness of at least about 80 percent, more preferably at least about 85 percent, even more preferably at least about 90 percent. Thus, the aerosol cooling element is capable of imparting the desired level of hardness to the aerosol-generating article.

If desired, the radial hardness of the aerosol cooling element in the aerosol-generating articles of the present invention can be further increased by surrounding the aerosol cooling element with a rigid filament, such as a filament having a grammage of at least about 80 grams per square meter (g/m2), or at least about 100 g/m2, or at least about 110 g/m2.

In the context of this document, the term "radial hardness" refers to the resistance to compression in the direction transverse to the longitudinal axis of the support member. The radial hardness of an aerosol-generating article around a support member can be determined by applying a load to the article at the location of the support member transverse to the longitudinal axis of the article and measuring the average (mean) diameters of the articles in the compressed state. The radial hardness is determined as follows:

where D _S is the original diameter (in the uncompressed state), and D _d is the diameter in the compressed state after applying a specified load for a specified period of time. The harder the material, the closer its hardness is to 100 percent.

In order to determine the hardness of a part (such as a support element provided in the form of a hollow tubular segment) of an aerosol article, the aerosol-generating articles shall be aligned parallel in a plane and the same part of each aerosol-generating article to be tested shall be subjected to a specified load for a specified period of time. This test is carried out using a known densimetric device DD60A (manufactured and marketed by Heinr Borgwaldt GmbH, Germany) equipped with a measuring head for aerosol-generating articles such as cigarettes and a receiver for the aerosol-generating article.

The load is applied using two cylindrical load bars that traverse the diameter of all the aerosol-generating articles simultaneously. According to the standard test method for this measuring device, the test should be conducted in such a way that twenty points of contact exist between the aerosol-generating articles and the cylindrical load bars. In some cases, the hollow tubular segments to be tested may be long enough that only ten aerosol-generating articles are required to achieve twenty points of contact; in this case, each smoking article will contact both load bars (since the segments are long enough to pass between the shafts). In other cases, if the support members are too short to achieve the above, then twenty aerosol-generating articles should be used to achieve twenty points of contact; in this case, each aerosol-generating article will contact only one of the load bars, as further described below.

Two additional fixed cylindrical rods are placed below the aerosol generating articles to support the aerosol generating articles and to counteract the load applied by each of the cylindrical rods to apply the load.

In a standard procedure for such a device, a total load of 2 kg is applied for 20 seconds. After 20 seconds (and while the load is being applied to the smoking articles), the depression of the cylindrical rods for applying the load is determined and then this value is used to calculate the hardness according to the above equation. The temperature is maintained at about 22 degrees Celsius ± 2 degrees. The above test is called the DD60A test. This standard method for measuring the hardness of a filter is used when the aerosol-generating article has not been consumed. Additional information on measuring the average radial hardness can be found, for example, in published US Patent Application No. 2016/0128378.

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

In a preferred embodiment, the aerosol cooling element is made of acetyl cellulose.

The ventilation zone comprises a plurality of perforations passing through the peripheral wall of the aerosol cooling element. Preferably, the ventilation zone comprises at least one annular row of perforations. In some embodiments, the ventilation zone may comprise two annular rows of perforations. For example, the perforations may be made on a production line during the manufacturing process of the aerosol-generating article. Preferably, each annular row of perforations comprises from 8 to 30 perforations.

If the aerosol-generating article comprises a unifying plug for attaching the aerosol-cooling element to one or more other components of the aerosol-generating article, the ventilation zone preferably comprises at least one corresponding annular row of perforations passing through the wrapper portion of the unifying plug. They can also be made on the production line during the manufacturing process of the smoking article. Preferably, the annular row or annular rows of perforations passing through the wrapper portion of the unifying plug are substantially in alignment with the row or rows of perforations passing through the peripheral wall of the aerosol-cooling element.

If the aerosol-generating article comprises a strip of tipping paper for attaching the aerosol-cooling element to the mouthpiece element of the aerosol-generating article, wherein said strip of tipping paper extends over an annular row or annular rows of perforations in the peripheral wall of the aerosol-cooling element, then the ventilation zone preferably comprises at least one corresponding annular row of perforations passing through said strip of tipping paper. They can also be made on a production line during the manufacturing process of the smoking article. Preferably, the annular row or annular rows of perforations passing through the strip of tipping paper are substantially in a state of alignment with the row or rows of perforations passing through the peripheral wall of the aerosol-cooling element.

In some embodiments, the distance between the ventilation zone and the upstream end of the hollow tubular segment of the aerosol cooling element is at least about 1 millimeter. Preferably, the distance between the ventilation zone and the upstream end of the hollow tubular segment of the aerosol cooling element is at least about 2 millimeters. More preferably, the distance between the ventilation zone and the upstream end of the hollow tubular segment of the aerosol cooling element is at least about 3 millimeters.

In some embodiments, the distance between the ventilation zone and the upstream end of the hollow tubular segment of the aerosol cooling element is less than about 6 millimeters or equal to about 6 millimeters. Preferably, the distance between the ventilation zone and the upstream end of the hollow tubular segment of the aerosol cooling element is less than about 5 millimeters or equal to about 5 millimeters. More preferably, the distance between the ventilation zone and the upstream end of the hollow tubular segment of the aerosol cooling element is less than about 4 millimeters or equal to about 4 millimeters.

In some embodiments, the distance between the ventilation zone and the upstream end of the hollow tubular segment of the aerosol cooling element is from about 1 millimeter to about 6 millimeters, preferably from about 1 millimeter to about 5 millimeters, more preferably from about 1 millimeter to about 4 millimeters. In other embodiments, the distance between the ventilation zone and the upstream end of the hollow tubular segment of the aerosol cooling element is from about 2 millimeters to about 6 millimeters, preferably from about 2 millimeters to about 5 millimeters, more preferably from about 2 millimeters to about 4 millimeters. In further embodiments, the distance between the ventilation zone and the upstream end of the hollow tubular segment of the aerosol cooling element is from about 3 millimeters to about 6 millimeters, preferably from about 3 millimeters to about 5 millimeters, more preferably from about 3 millimeters to about 4 millimeters.

The distance between the ventilation zone and the mouth end of the aerosol-generating article is preferably at least about 10 millimeters. More preferably, the distance between the ventilation zone and the mouth end of the aerosol-generating article is at least about 12 millimeters. Even more preferably, the distance between the ventilation zone and the mouth end of the aerosol-generating article is at least about 16 millimeters.

The distance between the ventilation zone and the mouth end of the aerosol-generating article is preferably less than about 26 millimeters or equal to about 26 millimeters. More preferably, the distance between the ventilation zone and the mouth end of the aerosol-generating article is about 24 millimeters or less. Even more preferably, the distance between the ventilation zone and the mouth end of the aerosol-generating article is less than about 22 millimeters or equal to about 22 millimeters. In particularly preferred embodiments, the distance between the ventilation zone and the mouth end of the aerosol-generating article is about 20 millimeters or less.

In some embodiments, the distance between the ventilation zone and the mouth end of the aerosol-generating article is from about 10 millimeters to about 26 millimeters, preferably from about 10 millimeters to about 24 millimeters, more preferably from about 10 millimeters to about 22 millimeters, even more preferably from about 10 millimeters to about 20 millimeters. In other embodiments, the distance between the ventilation zone and the mouth end of the aerosol-generating article is from about 12 millimeters to about 26 millimeters, preferably from about 12 millimeters to about 24 millimeters, more preferably from about 12 millimeters to about 22 millimeters, even more preferably from about 12 millimeters to about 20 millimeters. In further embodiments, the distance between the ventilation zone and the mouth end of the aerosol-generating article is from about 14 millimeters to about 26 millimeters, preferably from about 14 millimeters to about 24 millimeters, more preferably from about 14 millimeters to about 22 millimeters, even more preferably from about 14 millimeters to about 20 millimeters. In other further embodiments, the distance between the ventilation zone and the mouth end of the aerosol-generating article is from about 16 millimeters to about 26 millimeters, preferably from about 16 millimeters to about 24 millimeters, more preferably from about 16 millimeters to about 22 millimeters, even more preferably from about 16 millimeters to about 20 millimeters.

The distance between the ventilation zone and the upstream end of the downstream section is preferably at least about 6 millimeters. More preferably, the distance between the ventilation zone and the upstream end of the downstream section is at least about 8 millimeters. Even more preferably, the distance between the ventilation zone and the upstream end of the downstream section is at least about 10 millimeters.

The distance between the ventilation zone and the upstream end of the downstream section is preferably less than about 20 millimeters or equal to 20 millimeters. More preferably, the distance between the ventilation zone and the upstream end of the downstream section is less than about 18 millimeters or equal to 18 millimeters. Even more preferably, the distance between the ventilation zone and the upstream end of the downstream section is less than about 16 millimeters or equal to 16 millimeters.

In some embodiments, the distance between the ventilation zone and the upstream end of the downstream section is preferably from about 6 millimeters to about 20 millimeters, more preferably from about 8 millimeters to about 20 millimeters, even more preferably from about 10 millimeters to about 20 millimeters. In other embodiments, the distance between the ventilation zone and the upstream end of the downstream section is preferably from about 6 millimeters to about 18 millimeters, more preferably from about 8 millimeters to about 18 millimeters, even more preferably from about 10 millimeters to about 18 millimeters. In further embodiments, the distance between the ventilation zone and the upstream end of the downstream section is preferably from about 6 millimeters to about 16 millimeters, more preferably from about 8 millimeters to about 16 millimeters, even more preferably from about 10 millimeters to about 16 millimeters.

The distance between the ventilation zone and the downstream end of the current collector is preferably at least approximately 6 millimeters. More preferably, the distance between the ventilation zone and the downstream end of the current collector is at least approximately 8 millimeters. Even more preferably, the distance between the ventilation zone and the downstream end of the current collector is at least approximately 10 millimeters.

The distance between the ventilation zone and the downstream end of the current collector is preferably approximately 20 millimeters or equal to approximately 20 millimeters. More preferably, the distance between the ventilation zone and the downstream end of the current collector is less than approximately 18 millimeters or equal to approximately 18 millimeters. Even more preferably, the distance between the ventilation zone and the downstream end of the current collector is approximately 16 millimeters or equal to approximately 16 millimeters.

In some embodiments, the distance between the ventilation zone and the downstream end of the current collector is preferably from about 6 millimeters to about 20 millimeters, more preferably from about 8 millimeters to about 20 millimeters, even more preferably from about 10 millimeters to about 20 millimeters. In other embodiments, the distance between the ventilation zone and the downstream end of the current collector is preferably from about 6 millimeters to about 18 millimeters, more preferably from about 8 millimeters to about 18 millimeters, even more preferably from about 10 millimeters to about 18 millimeters. In further embodiments, the distance between the ventilation zone and the downstream end of the current collector is preferably from about 6 millimeters to about 16 millimeters, more preferably from about 8 millimeters to about 16 millimeters, even more preferably from about 10 millimeters to about 16 millimeters.

The aerosol generating article of the present invention may have a ventilation level of at least about 5 percent.

The term "ventilation level" is used throughout this specification to refer to the volumetric ratio between the airflow entering the aerosol-generating article through the ventilation zone (the 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.

Preferably, the aerosol-generating article of the present invention may have a ventilation level of at least about 10 percent, more preferably at least about 15 percent, even more preferably at least about 20 percent. In particularly preferred embodiments, the aerosol-generating article of the present invention has a ventilation level of at least about 25 percent.

The aerosol generating article preferably has a ventilation level of less than approximately 60 percent.

The aerosol-generating article of the present invention preferably has a ventilation level of less than or equal to about 45 percent. More preferably, the aerosol-generating article of the present invention has a ventilation level of less than or equal to about 40 percent, even more preferably less than or equal to about 35 percent.

In particularly preferred embodiments, the aerosol generating article has a ventilation level of approximately 30 percent.

In some embodiments, the aerosol-generating article has a ventilation level of about 20 percent to about 60 percent, preferably about 20 percent to about 45 percent, more preferably about 20 percent to about 40 percent. In other embodiments, the aerosol-generating article has a ventilation level of about 25 percent to about 60 percent, preferably about 25 percent to about 45 percent, more preferably about 25 percent to about 40 percent. In further embodiments, the aerosol-generating article has a ventilation level of about 30 percent to about 60 percent, preferably about 30 percent to about 45 percent, more preferably about 30 percent to about 40 percent.

In particularly preferred embodiments, the aerosol-generating article has a ventilation level of from about 28 percent to about 42 percent. In some particularly preferred embodiments, the aerosol-generating article has a ventilation level of about 30 percent.

Without wishing to be bound by theory, the present inventors have discovered that a temperature difference caused by the introduction of cooler outside air into the hollow tubular segment through the ventilation zone can have a beneficial effect on the nucleation and growth of aerosol particles.

The formation of an aerosol from a gaseous mixture containing various chemical compounds depends on the subtle interactions of nucleation, evaporation and condensation, and droplet coalescence, while taking into account changes in vapor concentration, temperature and velocity fields. The so-called classical nucleation theory is based on the assumption that the fraction of molecules in the gas phase is large enough for them to remain coherent for a long time with a sufficient probability (e.g., fifty-fifty probability). These molecules represent a kind of critical threshold molecular clusters among short-lived molecular aggregates, which means that smaller molecular clusters will generally be likely to disintegrate fairly quickly to form the gas phase, while larger clusters will generally be likely to grow. Such a critical cluster is identified as the key nucleation nucleus from which droplet growth is expected due to condensation of molecules from the vapor. Primary droplets that have just formed are assumed to appear with a certain initial diameter, and they can then grow by several orders of magnitude. It is possible to assist and enhance this process by rapidly cooling the surrounding vapor, causing condensation. In this regard, it should be kept in mind that evaporation and condensation are two sides of the same mechanism, namely gas-liquid mass transfer. While evaporation refers to a net mass transfer from liquid droplets to the gas phase, condensation is a net mass transfer from the gas phase to the droplet phase. Evaporation (or condensation) will cause droplets to shrink (or grow), but will not change the number of droplets.

In this scenario, which may be further complicated by droplet coalescence phenomena, temperature and cooling rate may play an important role in determining the response of the system. In general, different cooling rates may result in significantly different temporal behaviors in terms of liquid phase (droplet) formation, since the nucleation process is typically nonlinear. Without reference to theory, it is assumed that cooling may result in a rapid decrease in the droplet number concentration, followed by a strong short-term increase in droplet growth (nucleation burst). This nucleation burst is assumed to be larger at lower temperatures. Furthermore, higher cooling rates are assumed to favor an earlier onset of nucleation. Conversely, a decrease in the cooling rate is assumed to have a favorable effect on the final size that the aerosol droplets eventually reach.

Thus, the rapid cooling caused by the flow of outside air into the hollow tubular segment through the ventilation zone can be used to advantage to promote the nucleation and growth of aerosol droplets. However, at the same time, the flow of outside air into the hollow tubular segment has a significant disadvantage consisting in diluting the aerosol flow delivered to the consumer.

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

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

This is of particular advantage in the case of "short" aerosol-generating articles, such as articles in which the length of the rod of the aerosol-generating substrate is less than about 40 millimeters, preferably less than 25 millimeters, even more preferably less than 20 millimeters, or in which 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, little time and space is provided for the formation of the aerosol and for the particulate phase in the aerosol to become available for delivery to the consumer.

In addition, since the ventilated hollow tubular element does not substantially contribute to the overall RTD of the aerosol-generating article, the aerosol-generating articles of the present invention provide the advantage of being able to finely adjust the overall RTD of the article by adjusting the length and density of the rod of the aerosol-generating substrate, or the length and, if necessary, the length and density of the segment of the filter material forming part of the mouthpiece, or the length and density of the segment of the filter material provided upstream of the aerosol-generating substrate and the susceptor. In this way, it is possible for aerosol-generating articles that have a given RTD to be manufactured in a reproducible manner and with high accuracy, which allows satisfactory RTD levels to be provided to the consumer even in the presence of ventilation.

In the aerosol-generating articles according to the present invention, the overall RTD of the article depends essentially on the RTD of the rod and, optionally, on the RTD of the mouthpiece and/or the upstream plug. This is explained by the fact that the hollow tubular segment of the aerosol cooling element and the hollow tubular segment of the support element are essentially empty, and thus they essentially make only a minor contribution to the overall RTD of the aerosol-generating article.

In practice, the hollow tubular segment of the aerosol cooling element may be adapted to generate an RTD in the range from about 0 millimeters of water (about 0 Pa) to about 20 millimeters of water (about 200 Pa). Preferably, the hollow tubular segment of the aerosol cooling element is configured to create an RTD from about 0 millimeters of _H2O (about 0 Pa) to about 10 millimeters of _H2O (about 100 Pa).

In some embodiments, the aerosol-generating article may further comprise an additional cooling element that forms a plurality of longitudinally extending channels in order to make a significant surface area available for heat exchange. In other words, one such additional cooling element is configured to function essentially as a heat exchanger. Said plurality of longitudinally extending channels may be formed by a sheet material that is accordion-folded, gathered or bent to form channels. Said plurality of longitudinally extending channels may be formed by a single sheet that is accordion-folded, gathered or bent to form a plurality of channels. The sheet may also be corrugated before accordion-folding, gathering or bending. Alternatively, said plurality of longitudinally extending channels may be formed by a plurality of sheets that are corrugated, accordion-folded, gathered or bent to form a plurality of channels. In some embodiments, said plurality of longitudinally extending channels may be formed by a plurality of sheets that are corrugated, accordion-folded, gathered or folded together, i.e., two or more sheets that have been placed on top of each other and then corrugated, accordion-folded, gathered or folded as a single unit. As used herein, the term "sheet" means a flat element whose width and length are substantially greater than its thickness.

In other embodiments, the aerosol cooling element may be provided in the form of a single such cooling element comprising a plurality of longitudinally extending channels.

As used herein, the term "longitudinal direction" refers to a direction that runs along or parallel to the axis of the rod cylinder. As used herein, the term "corrugated" means a sheet that has a plurality of substantially parallel folds or corrugations. Preferably, when the aerosol-generating article is assembled, said substantially parallel folds or corrugations extend in the longitudinal direction relative to the rod. As used herein, the terms "gathered," "accordion-folded," or "folded" mean that the sheet of material is rolled, folded, or otherwise compressed or narrowed substantially in the transverse direction relative to the axis of the rod cylinder. The sheet may be corrugated before being assembled, accordion-folded, or folded. The sheet may be gathered, accordion-folded, or folded without being pre-corrugated.

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

The additional cooling element preferably creates a low resistance to the passage of air through this additional cooling element. Preferably, the additional cooling element does not substantially affect the resistance to draw of the aerosol-generating article. To achieve this, it is preferable that the porosity in the longitudinal direction is greater than 50 percent, and that the air flow path through the additional cooling element is relatively free. The longitudinal porosity of the additional cooling element can be determined by the ratio of the cross-sectional area of the material forming the additional cooling element and the area of the internal cross-section of the aerosol-generating article in the part that contains the additional cooling element.

The additional cooling element preferably comprises a sheet material selected from the group consisting of a metal foil, a polymer sheet and substantially non-porous paper or cardboard. In some embodiments, the aerosol cooling element may comprise a sheet material selected from the group consisting of polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), polyethylene terephthalate (PET), polylactic acid (PLA), acetyl cellulose (CA) and aluminum foil. In a particularly preferred embodiment, the additional cooling element comprises a PLA sheet.

Preferably, as briefly described above, the downstream section of the aerosol-generating article according to the present invention further comprises a support element arranged in a state of alignment with the rod of the aerosol-generating article, downstream relative to it. In particular, the support element may be located downstream relative to the aerosol-generating substrate immediately after it, and it may be adjacent to the rod of the aerosol-generating substrate.

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

The support element may comprise a hollow tubular element. In a preferred embodiment, the support element comprises a hollow acetyl cellulose tube.

The support element is arranged substantially in a state of alignment with the rod. This means that the length dimension of the support element runs approximately parallel to the longitudinal direction of the rod and the article, for example parallel to the longitudinal direction of the rod with a deviation of plus or minus 10 degrees. In preferred embodiments, the support element runs along the longitudinal axis of the rod.

The support member preferably has an outer diameter that is approximately equal to the outer diameter of the aerosol-generating substrate rod and the outer diameter of the aerosol-generating article.

The support element may have an outer diameter of 5 millimeters to 12 millimeters, such as 5 millimeters to 10 millimeters or 6 millimeters to 8 millimeters. In a preferred embodiment, the support element has an outer diameter of 7.2 millimeters plus or minus 10 percent. The support element may have a length of 5 millimeters to 15 millimeters. In a preferred embodiment, the support element has a length of 8 millimeters.

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

The support element may have a length from approximately 5 millimeters to approximately 15 millimeters.

Preferably, the support member has a length of at least about 6 millimeters, more preferably at least about 7 millimeters.

In preferred embodiments, the support member has a length of less than about 12 millimeters, more preferably less than about 10 millimeters.

In some embodiments, the support member has a length of about 5 millimeters to about 15 millimeters, more preferably about 6 millimeters to about 15 millimeters, more preferably about 7 millimeters to about 15 millimeters. In other embodiments, the support member has a length of about 5 millimeters to about 12 millimeters, preferably about 6 millimeters to about 12 millimeters, more preferably about 7 millimeters to about 12 millimeters. In further embodiments, the support member has a length of about 5 millimeters to about 10 millimeters, preferably about 6 millimeters to about 10 millimeters, more preferably about 7 millimeters to about 10 millimeters.

In a preferred embodiment, the support member has a length of approximately 8 millimeters.

The ratio between the length of the support member and the length of the aerosol generating substrate rod may be from about 0.25 to about 1.

Preferably, the ratio between the length of the support element and the length of the rod of the aerosol-generating substrate is at least about 0.3, more preferably at least about 0.4, even more preferably at least about 0.5. In preferred embodiments, the ratio between the length of the support element and the length of the rod of the aerosol-generating substrate is less than about 0.9, more preferably less than about 0.8, even more preferably less than about 0.7.

In some embodiments, the ratio between the length of the support element and the length of the rod of the aerosol-generating substrate is from about 0.3 to about 0.9, preferably from about 0.4 to about 0.9, more preferably from about 0.5 to about 0.9. In other embodiments, the ratio between the length of the support element and the length of the rod of the aerosol-generating substrate is from about 0.3 to about 0.8, preferably from about 0.4 to about 0.8, more preferably from about 0.5 to about 0.8. In further embodiments, the ratio between the length of the support element and the length of the rod of the aerosol-generating substrate is from about 0.3 to about 0.7, preferably from about 0.4 to about 0.7, more preferably from about 0.5 to about 0.7.

In particularly preferred embodiments, the ratio between the length of the support element and the length of the aerosol-generating substrate rod is approximately 0.66.

The ratio between the length of the support member and the overall length of the aerosol generating article may be from about 0.125 to about 0.375.

Preferably, the ratio between the length of the support element and the total length of the aerosol-generating article is at least about 0.13, more preferably at least about 0.14, even more preferably at least about 0.15. The ratio between the length of the support element and the total length of the aerosol-generating article is preferably less than about 0.3, more preferably less than about 0.25, even more preferably less than about 0.20.

In some embodiments, the ratio between the length of the support element and the overall length of the aerosol-generating article is preferably from about 0.13 to about 0.3, more preferably from about 0.14 to about 0.3, even more preferably from about 0.15 to about 0.3. In other embodiments, the ratio between the length of the support element and the overall length of the aerosol-generating article is preferably from about 0.13 to about 0.25, more preferably from about 0.14 to about 0.25, even more preferably from about 0.15 to about 0.25. In further embodiments, the ratio between the length of the support element and the overall length of the aerosol-generating article is preferably from about 0.13 to about 0.2, more preferably from about 0.14 to about 0.2, even more preferably from about 0.15 to about 0.2.

In a particularly preferred embodiment, the ratio between the length of the support element and the overall length of the aerosol generating article is approximately 0.18.

Preferably, in the aerosol-generating articles according to the present invention, the support member has an average radial hardness of at least about 80 percent, more preferably at least about 85 percent, even more preferably at least about 90 percent. Therefore, the support member is capable of imparting the required level of hardness to the aerosol-generating article.

If desired, the radial hardness of the support element of the aerosol-generating articles according to the present invention can be further increased by surrounding the support element with a rigid filament, such as a filament having a grammage of at least about 80 grams per square meter (g/m2), or at least about 100 g/m2, or at least about 110 g/m2.

During the insertion of the aerosol-generating article according to the present invention into the aerosol-generating device for heating the aerosol-generating substrate, the user may be required to apply some force to overcome the resistance of the aerosol-generating substrate of the aerosol-generating article for insertion. This may result in damage to one or both of the aerosol-generating article and the aerosol-generating device. In addition, the application of force during the insertion of the aerosol-generating article into the aerosol-generating device may result in the displacement of the aerosol-generating substrate inside the aerosol-generating article. This may result in improper alignment of the heating element of the aerosol-generating device with the current collector provided inside the aerosol-generating substrate, which in turn may result in uneven and ineffective heating of the aerosol-generating substrate of the aerosol-generating article. The support element is advantageously configured to resist movement of the aerosol-generating substrate further downstream during insertion of the article into the aerosol-generating device.

In the aerosol-generating articles according to the present invention, the overall RTD of the article depends essentially on the RTD of the rod and, optionally, on the RTD of the mouthpiece and/or the upstream plug. This is explained by the fact that the hollow tubular segment of the aerosol cooling element and the hollow tubular segment of the support element are essentially empty, and thus they essentially make only a minor contribution to the overall RTD of the aerosol-generating article.

In practice, the hollow tubular segment of the support member may be adapted to generate an RTD in the range from about 0 millimeters of water (about 0 Pa) to about 20 millimeters of water (about 200 Pa). Preferably, the hollow tubular segment of the support member is configured to generate an RTD from about 0 millimeters of _H2O (about 0 Pa) to about 10 millimeters of _H2O (about 100 Pa).

In some embodiments, the downstream section comprises both a support member comprising a first hollow tubular segment and an aerosol cooling member comprising a second hollow tubular segment, such that the support member and the aerosol cooling member together form an intermediate hollow section, wherein the inner diameter ( _DSTS ) of the second hollow tubular segment is preferably larger than the inner diameter ( _DFTS ) of the first hollow tubular segment.

In more detail, the ratio between the inner diameter ( _DSTS ) of the second hollow tubular segment and the inner diameter ( _DFTS ) of the first hollow tubular segment is preferably at least about 1.25. More preferably, the ratio between the inner diameter ( _DSTS ) of the second hollow tubular segment and the inner diameter ( _DFTS ) of the first hollow tubular segment is preferably at least about 1.3. Even more preferably, the ratio between the inner diameter ( _DSTS ) of the second hollow tubular segment and the inner diameter ( _DFTS ) of the first hollow tubular segment is preferably at least about 1.4. In particularly preferred embodiments, the ratio between the inner diameter ( _DSTS ) of the second hollow tubular segment and the inner diameter ( _DFTS ) of the first hollow tubular segment is at least about 1.5, more preferably at least about 1.6.

The ratio between the inner diameter ( _DSTS ) of the second hollow tubular segment and the inner diameter ( _DFTS ) of the first hollow tubular segment is preferably less than or equal to about 2.5. More preferably, the ratio between the inner diameter ( _DSTS ) of the second hollow tubular segment and the inner diameter ( _DFTS ) of the first hollow tubular segment is preferably less than or equal to about 2.25. Even more preferably, the ratio between the inner diameter ( _DSTS ) of the second hollow tubular segment and the inner diameter ( _DFTS ) of the first hollow tubular segment is preferably less than or equal to about 2.

In some embodiments, the ratio between the inner diameter ( _DSTS ) of the second hollow tubular segment and the inner diameter ( _DFTS ) of the first hollow tubular segment is from about 1.25 to about 2.5. Preferably, the ratio between the inner diameter ( _DSTS ) of the second hollow tubular segment and the inner diameter ( _DFTS ) of the first hollow tubular segment is from about 1.3 to about 2.5. More preferably, the ratio between the inner diameter ( _DSTS ) of the second hollow tubular segment and the inner diameter ( _DFTS ) of the first hollow tubular segment is from about 1.4 to about 2.5. In particularly preferred embodiments, the ratio between the inner diameter ( _DSTS ) of the second hollow tubular segment and the inner diameter ( _DFTS ) of the first hollow tubular segment is from about 1.5 to about 2.5.

In other embodiments, the ratio between the inner diameter ( _DSTS ) of the second hollow tubular segment and the inner diameter ( _DFTS ) of the first hollow tubular segment is from about 1.25 to about 2.25. Preferably, the ratio between the inner diameter ( _DSTS ) of the second hollow tubular segment and the inner diameter ( _DFTS ) of the first hollow tubular segment is from about 1.3 to about 2.25. More preferably, the ratio between the inner diameter ( _DSTS ) of the second hollow tubular segment and the inner diameter ( _DFTS ) of the first hollow tubular segment is from about 1.4 to about 2.25. In particularly preferred embodiments, the ratio between the inner diameter ( _DSTS ) of the second hollow tubular segment and the inner diameter ( _DFTS ) of the first hollow tubular segment is from about 1.5 to about 2.25.

In further embodiments, the ratio between the inner diameter ( _DSTS ) of the second hollow tubular segment and the inner diameter ( _DFTS ) of the first hollow tubular segment is from about 1.25 to about 2. Preferably, the ratio between the inner diameter ( _DSTS ) of the second hollow tubular segment and the inner diameter ( _DFTS ) of the first hollow tubular segment is from about 1.3 to about 2. More preferably, the ratio between the inner diameter ( _DSTS ) of the second hollow tubular segment and the inner diameter ( _DFTS ) of the first hollow tubular segment is from about 1.4 to about 2. In particularly preferred embodiments, the ratio between the inner diameter ( _DSTS ) of the second hollow tubular segment and the inner diameter ( _DFTS ) of the first hollow tubular segment is from about 1.5 to about 2.

In those embodiments in which the article further comprises an elongated current collector located longitudinally within the aerosol-generating substrate, the ratio between the inner diameter ( _DFTS ) of the first hollow tubular segment and the width of the current collector is preferably at least about 0.2. More preferably, the ratio between the inner diameter ( _DFTS ) of the first hollow tubular segment and the width of the current collector is at least about 0.3. Even more preferably, the ratio between the inner diameter ( _DFTS ) of the first hollow tubular segment and the width of the current collector is at least about 0.4.

Additionally or alternatively, the ratio between the inner diameter ( _DSTS ) of the second hollow tubular segment and the width of the current collector is preferably at least about 0.2. More preferably, the ratio between the inner diameter ( _DSTS ) of the second hollow tubular segment and the width of the current collector is at least about 0.5. Even more preferably, the ratio between the inner diameter ( _DSTS ) of the second hollow tubular segment and the width of the current collector is at least about 0.8.

Preferably, the ratio between the cavity volume of the first hollow tubular segment and the cavity volume of the second hollow tubular segment is at least approximately 0.1. More preferably, the ratio between the cavity volume of the first hollow tubular segment and the cavity volume of the second hollow tubular segment is at least approximately 0.2. Even more preferably, the ratio between the cavity volume of the first hollow tubular segment and the cavity volume of the second hollow tubular segment is at least approximately 0.3.

The ratio between the cavity volume of the first hollow tubular segment and the cavity volume of the second hollow tubular segment is preferably less than or equal to approximately 0.9. More preferably, the ratio between the cavity volume of the first hollow tubular segment and the cavity volume of the second hollow tubular segment is preferably less than or equal to approximately 0.7. Even more preferably, the ratio between the cavity volume of the first hollow tubular segment and the cavity volume of the second hollow tubular segment is preferably less than or equal to approximately 0.5.

In preferred embodiments, the downstream section of the aerosol-generating articles of the present invention includes an intermediate hollow section having both the aerosol cooling member described above and the support member described above.

Preferably, the length of the mouthpiece element is at least 0.4 of the total length of the intermediate hollow section, more preferably at least 0.5 of the length of the intermediate hollow section, more preferably at least 0.6 of the length of the intermediate hollow section, more preferably at least 0.7 of the length of the intermediate hollow section.

The downstream section of the aerosol-generating article according to the present invention preferably includes a mouthpiece element. The mouthpiece element is preferably arranged at the downstream end or mouthpiece end of the aerosol-generating article. The mouthpiece element preferably comprises at least one mouthpiece filter segment for filtering the aerosol generated from the aerosol-generating substrate. For example, the mouthpiece element may comprise one or more segments of fibrous filter material. Suitable fibrous filter materials should be known to those skilled in the art. Particularly preferably, said at least one mouthpiece filter segment comprises an acetate cellulose filter segment made of acetate cellulose tow.

In some preferred embodiments, the mouthpiece element consists of a single filter mouthpiece segment. In alternative embodiments, the mouthpiece element includes two or more filter mouthpiece segments aligned coaxially with one another in end-to-end contact.

In some embodiments of the present invention, the downstream section may comprise a cavity at the mouth end, located at a downstream end, located downstream of the mouth end element, as described above. The cavity at the mouth end may be formed by a hollow tubular element provided at the downstream end of the mouth end. Alternatively, the cavity at the mouth end may be formed by an outer wrapper of the mouth end element, wherein this outer wrapper extends in a direction downstream of the mouth end element.

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

In the aerosol generating article according to the present invention, the mouthpiece element forms part of a downstream section and is therefore located downstream of the rod of the aerosol generating substrate.

In some preferred embodiments, the downstream section of the aerosol-generating article further comprises a support element located downstream of the rod of the aerosol-generating substrate immediately after it. The mouthpiece element is preferably located downstream of the support element. Preferably, the downstream section further comprises an aerosol cooling element located downstream of the support element immediately after it. The mouthpiece element is preferably located downstream of both the support element and the aerosol cooling element. Particularly preferably, the mouthpiece element is located downstream of the aerosol cooling element immediately after it. For example, the mouthpiece element may adjoin the downstream end of the aerosol cooling element.

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

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

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

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

Preferably, the mouthpiece element has an RTD of less than about 25 millimeters _H2O . More preferably, the mouthpiece element has an RTD of less than about 20 millimeters _H2O . Even more preferably, the mouthpiece element has an RTD of less than about 15 millimeters _H2O .

RTD values of from about 10 millimeters _H2O to about 15 millimeters _H2O are particularly preferred since a mouthpiece element having one such RTD value is expected to make a minimal contribution to the overall RTD of the aerosol-generating article and will have substantially no filtering effect on the aerosol delivered to the consumer.

The mouthpiece element preferably has an outer diameter that is approximately equal to the outer diameter of the aerosol-generating article. The mouthpiece element may have an outer diameter of about 5 millimeters to about 10 millimeters or about 6 millimeters to about 8 millimeters. In a preferred embodiment, the mouthpiece element has an outer diameter of about 7.2 millimeters.

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

In some embodiments, the mouthpiece element preferably has a length of about 5 millimeters to about 25 millimeters, more preferably about 8 millimeters to about 25 millimeters, even more preferably about 10 millimeters to about 25 millimeters. In other embodiments, the mouthpiece element preferably has a length of about 5 millimeters to about 10 millimeters, more preferably about 8 millimeters to about 20 millimeters, even more preferably about 10 millimeters to about 20 millimeters. In further embodiments, the mouthpiece element preferably has a length of about 5 millimeters to about 15 millimeters, more preferably about 8 millimeters to about 15 millimeters, even more preferably about 10 millimeters to about 15 millimeters.

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

In some preferred embodiments of the present invention, the mouthpiece element has a length of at least 10 millimeters. Therefore, in such embodiments, the mouthpiece element is relatively long compared to the mouthpiece element provided in the articles of the prior art. By providing a relatively long mouthpiece element in the aerosol-generating articles according to the present invention, it is possible to provide a number of advantages for the consumer. The mouthpiece element is usually more resistant to deformation or better adapted to restore its original shape after deformation than other elements that may be provided further downstream of the aerosol-generating substrate rod, such as an aerosol cooling element or a support element. Therefore, increasing the length of the mouthpiece element provides an improved grip by the consumer and facilitates insertion of the aerosol-generating article into the heating device. A longer mouthpiece may additionally be used to provide a higher level of filtration and removal of unwanted aerosol constituents such as phenols to enable higher quality aerosol delivery. In addition, the use of a longer mouthpiece element makes it possible to provide a more complex mouthpiece as there is more space to incorporate mouthpiece components such as capsules, strings and stoppers.

In particularly preferred embodiments of the present invention, a mouthpiece having a length of at least 10 millimeters is combined with a relatively short aerosol cooling element, for example an aerosol cooling element having a length of less than 10 millimeters. It has been found that this combination provides a more rigid mouthpiece, which reduces the risk of deformation of the aerosol cooling element during use and facilitates a more efficient puff by the consumer.

The ratio between the length of the mouthpiece element and the length of the aerosol generating substrate rod may be from about 0.5 to about 1.5.

Preferably, the ratio between the length of the mouthpiece element and the length of the rod of the aerosol-generating substrate is at least about 0.6, more preferably at least about 0.7, even more preferably at least about 0.8. In preferred embodiments, the ratio between the length of the mouthpiece element and the length of the rod of the aerosol-generating substrate is less than about 1.4, more preferably less than about 1.3, even more preferably less than about 1.2.

In some embodiments, the ratio between the length of the mouthpiece element and the length of the rod of the aerosol-generating substrate is from about 0.6 to about 1.4, preferably from about 0.7 to about 1.4, more preferably from about 0.8 to about 1.4. In other embodiments, the ratio between the length of the mouthpiece element and the length of the rod of the aerosol-generating substrate is from about 0.6 to about 1.3, preferably from about 0.7 to about 1.3, more preferably from about 0.8 to about 1.3. In further embodiments, the ratio between the length of the mouthpiece element and the length of the rod of the aerosol-generating substrate is from about 0.6 to about 1.2, preferably from about 0.7 to about 1.2, more preferably from about 0.8 to about 1.2.

In particularly preferred embodiments, the ratio between the length of the mouthpiece element and the length of the rod of the aerosol-generating substrate is approximately 1.

The ratio between the length of the mouthpiece element and the overall length of the aerosol generating article may be from about 0.2 to about 0.35.

Preferably, the ratio between the length of the mouthpiece element and the total length 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 mouthpiece element and the total length 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.

In some embodiments, the ratio between the length of the mouthpiece element and the overall length 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. In other embodiments, the ratio between the length of the mouthpiece element and the overall length 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. In further embodiments, the ratio between the length of the mouthpiece element and the overall length 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.

In a particularly preferred embodiment, the ratio between the length of the mouthpiece element and the overall length of the aerosol generating article is approximately 0.27.

The aerosol-generating article may further comprise an upstream section at a location upstream of the aerosol-generating substrate rod. The upstream section may comprise one or more upstream elements. In some embodiments, the upstream section may comprise an upstream element that is upstream of the aerosol-generating substrate rod immediately before it.

The aerosol-generating article of the present invention preferably comprises an upstream element, which is located upstream of the aerosol-generating substrate in its vicinity, wherein said upstream section comprises at least one upstream element. The upstream element advantageously prevents direct physical contact with the upstream end of the aerosol-generating substrate. In particular, if the aerosol-generating substrate comprises a susceptor element, said upstream element makes it possible to prevent direct physical contact with the upstream end of the susceptor element. This helps to prevent displacement or deformation of the susceptor element during handling or transportation of the aerosol-generating article. This, in turn, helps to maintain the shape and location of the susceptor element. In addition, the presence of the upstream element helps to prevent any loss of substrate, which can be advantageous, for example, if the substrate comprises particulate plant material.

The upstream element may also provide an improved appearance to the upstream end of the aerosol-generating article. In addition, the upstream element may optionally be used to provide information about the aerosol-generating article, such as brand, flavor, and content information, or information about the aerosol-generating device with which the article is intended.

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

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

Advantageously, the porosity or permeability of the upstream element may be varied to provide the desired overall draw resistance of the aerosol generating article.

Preferably, the RTD of the upstream element is at least about 5 millimeters _H2O . More preferably, the RTD of the upstream element is at least about 10 millimeters _H2O . Even more preferably, the RTD of the upstream element is at least about 15 millimeters _H2O . In particularly preferred embodiments, the RTD of the upstream element is at least about 20 millimeters H[g1]2[/g1]O.

The RTD of the upstream element is preferably less than or equal to about 80 millimeters _H2O . More preferably, the RTD of the upstream element is less than or equal to about 60 millimeters _H2O . Even more preferably, the RTD of the upstream element is less than or equal to about 40 millimeters _H2O .

In some embodiments, the RTD of the upstream element is from about 5 millimeters _H2O to about 80 millimeters _H2O , preferably from about 10 millimeters _H2O to about 80 millimeters _H2O , more preferably from about 15 millimeters _H2O to about 80 millimeters _H2O , even more preferably from about 20 millimeters _H2O to about 80 millimeters _H2O . In other embodiments, the RTD of the upstream element is from about 5 millimeters _H2O to about 60 millimeters _H2O , preferably from about 10 millimeters _H2O to about 60 millimeters _H2O , more preferably from about 15 millimeters _H2O to about 60 millimeters _H2O , even more preferably from about 20 millimeters _H2O to about 60 millimeters _H2O . In further embodiments, the RTD of the upstream element is from about 5 millimeters _H2O to about 40 millimeters _H2O , preferably from about 10 millimeters _H2O to about 40 millimeters _H2O , more preferably from about 15 millimeters _H2O to about 40 millimeters _H2O , even more preferably from about 20 millimeters _H2O to about 40 millimeters _H2O .

In alternative embodiments, the upstream element may be made of an air-impermeable material. In such embodiments, the aerosol-generating article may be designed so that air flows into the rod of the aerosol-generating substrate through suitable ventilation means provided in the wrapper.

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

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

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

Preferably, the upstream element has a length of about 1 millimeter to about 10 millimeters, more preferably about 3 millimeters to about 8 millimeters, more preferably about 4 millimeters to about 6 millimeters. In a particularly preferred embodiment, the upstream element has a length of about 5 millimeters. As an advantage, the length of the upstream element can be varied to provide the desired overall length of the aerosol-generating article. For example, if it is desired to reduce the length of one of the other components of the aerosol-generating article, the length of the upstream element can be increased in order to maintain the overall length of the article at the same level.

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

The upstream element is preferably surrounded by a wrapper. The wrapper surrounding the upstream element is preferably a rigid wicker, for example a wicker having a grammage of at least about 80 grams per square meter (g/m2), or at least about 100 g/m2, or at least about 110 g/m2. This imparts structural rigidity to the upstream element.

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

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

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

In some embodiments, 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. In other embodiments, 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. In further embodiments, 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. In the exemplary embodiment, the overall length of the aerosol generating article is approximately 45 millimeters.

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

In some embodiments, the aerosol-generating article has an outer diameter of about 5 millimeters to about 12 millimeters, preferably about 6 millimeters to about 12 millimeters, more preferably about 7 millimeters to about 12 millimeters. In other embodiments, the aerosol-generating article has an outer diameter of about 5 millimeters to about 10 millimeters, preferably about 6 millimeters to about 10 millimeters, more preferably about 7 millimeters to about 10 millimeters. In further embodiments, the aerosol-generating article has an outer diameter of about 5 millimeters to about 8 millimeters, preferably about 6 millimeters to about 8 millimeters, more preferably about 7 millimeters to about 8 millimeters.

In some preferred embodiments of the present invention, the diameter (D _ME ) of the aerosol-generating article at the mouth end is (preferably) greater than the diameter (D _DE ) of the aerosol-generating article at the distal end. More specifically, 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 about 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 (preferably) at least about 1.01. More preferably, the ratio (D _ME /D _DE ) between the diameter of the aerosol-generating article at the mouth end and the diameter of the aerosol-generating article at the distal end is at least about 1.02. Even more preferably, the ratio (D _ME /D _DE ) between the diameter of the aerosol-generating article at the mouth end and the diameter of the aerosol-generating article at the distal end is at least about 1.05.

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

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

In other embodiments, the ratio (D _ME /D _DE ) between the diameter of the aerosol-generating article at the mouth end and the diameter of the aerosol-generating article at the distal end is from about 1.01 to 1.25, more preferably from 1.02 to 1.25, even more preferably from 1.05 to 1.25. In further embodiments, the ratio (D _ME /D _DE ) between the diameter of the aerosol-generating article at the mouth end and the diameter of the aerosol-generating article at the distal end is from about 1.01 to 1.20, more preferably from 1.02 to 1.20, even more preferably from 1.05 to 1.20. In other additional embodiments, the ratio (D _ME /D _DE ) between the diameter of the aerosol-generating article at the mouth end and the diameter of the aerosol-generating article at the distal end is from about 1.01 to 1.15, more preferably from 1.02 to 1.15, even more preferably from 1.05 to 1.15.

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

In some preferred embodiments of the present invention, the elements of the aerosol-generating article described above are arranged such that the center of mass of the aerosol-generating article is at least about 60 percent of the distance along the length of the aerosol-generating article from 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 least about 62 percent of the distance along the length of the aerosol-generating article from the downstream end, more preferably at least about 65 percent of the distance along the length of the aerosol-generating article from the downstream end.

Preferably, the center of mass is located no more than approximately 70 percent of the distance along the length of the aerosol generating article from the downstream end.

Providing an arrangement of elements such that the center of mass is closer to the upstream end than to the downstream end results in the aerosol-generating article having a weight imbalance with the heavier upstream end. This weight imbalance may advantageously provide tactile feedback to the consumer so that he or she can differentiate between the upstream and downstream ends and thus be able to insert the correct end into the aerosol-generating device. This may be particularly useful if an upstream element is provided such that the upstream and downstream ends of the aerosol-generating article are visually similar to each other.

In those embodiments of the aerosol-generating articles according to the present invention, in which both of the aerosol cooling element and the support element are present, they are preferably wrapped together in a unifying wrapper. The unifying wrapper surrounds the aerosol cooling element and the support element, but does not surround anything further downstream, such as the mouthpiece element.

In these embodiments, the aerosol cooling element and the support element are combined before they are surrounded by the combining wrapper and before they are further combined with the mouthpiece segment.

From a manufacturing perspective, this provides an advantage as it allows shorter aerosol generating products to be assembled.

In general, it may be difficult to manipulate individual elements that are shorter in length than their diameter. For example, for elements with a diameter of 7 millimeters, a length of approximately 7 millimeters represents a threshold value that is preferably not approached too closely. However, a 10 millimeter aerosol cooling element can be combined with a pair of 7 millimeter support elements on each side (and possibly other elements such as an aerosol generating substrate rod, etc.) to provide a 24 millimeter hollow segment, which is then cut into two intermediate 12 millimeter hollow sections.

In particularly preferred embodiments, the other components of the aerosol-generating article are individually surrounded by their own wrapper. In other words, the upstream element, the rod of the aerosol-generating substrate, the support element and the aerosol cooling element are all individually wrapped. The support element and the aerosol cooling element are combined to form an intermediate hollow section. This is achieved by wrapping the support element and the aerosol cooling element by means of a unifying wrapper. The upstream element, the rod of the aerosol-generating substrate and the intermediate hollow section are then combined by means of an outer wrapper. They are then combined with the mouthpiece element, which has its own wrapper, by means of a rim paper.

Preferably, at least one of the components of the aerosol generating article is wrapped in a hydrophobic wrapper.

The term "hydrophobic" refers to a surface that exhibits water-repellent properties. One effective way to determine this is to measure the water contact angle. The "water contact angle" is the angle typically measured through a liquid where the liquid/gas interface meets a solid surface. It quantifies the wettability of a solid surface by a liquid through Young's equation. Hydrophobicity or water contact angle can be determined using TAPPI Test Method T558 and the result can be reported as the contact angle at the interface, which is expressed in "degrees" and can range from approximately zero to approximately 180 degrees.

In preferred embodiments, the hydrophobic wrapper is a wrapper comprising a paper layer having a water contact angle of about 30 degrees or greater, preferably about 35 degrees or greater, or about 40 degrees or greater, or about 45 degrees or greater.

For example, the paper layer may contain, for example, PVOH (polyvinyl alcohol) or silicon. PVOH may be applied to the paper layer as a surface coating, or the paper layer may be surface treated with PVOH or silicon.

In a particularly preferred embodiment, the aerosol-generating article according to the present invention comprises, in a linear sequential arrangement, an upstream element, a rod of an aerosol-generating substrate located downstream of the upstream element immediately after it, a support element located downstream of the rod of an aerosol-generating substrate immediately after it, an aerosol cooling element located downstream of the support element immediately after it, a mouthpiece element located downstream of the aerosol cooling element immediately after it, and an outer wrapper surrounding said upstream element, support element, aerosol cooling element and mouthpiece element.

More specifically, the aerosol-generating substrate rod may be adjacent to the 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 has a substantially cylindrical shape with an outer diameter of approximately 7.25 millimeters.

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

The upstream element is present in the form of a cellulose acetate plug, which is wrapped in a rigid wrapper.

The aerosol-generating article comprises an elongated current collector, located substantially longitudinally inside the rod of the aerosol-generating substrate and in thermal contact with the aerosol-generating substrate. The current collector is present in the form of a strip or blade and has a length substantially equal to the length of the rod of the aerosol-generating substrate and a thickness of approximately 60 micrometers.

The support element is in the form of a hollow acetyl cellulose tube and has an internal diameter of approximately 1.9 millimeters. Thus, the thickness of the peripheral wall of the support element is approximately 2.675 millimeters.

The aerosol cooling element is present in the form of a thinner hollow acetyl cellulose tube and has an internal diameter of approximately 3.25 millimeters. Thus, the thickness of the peripheral wall of the aerosol cooling element is approximately 2 millimeters.

The mouthpiece is present in the form of a filter segment made of low-density acetyl cellulose.

The aerosol generating substrate rod comprises an aerosol generating substrate of at least one of the types described above, such as homogenized tobacco, a gel composition, or homogenized plant material containing particles of a plant other than tobacco.

The invention will now be further described with reference to the drawings in the accompanying figures, in which:

Fig. 1 shows a schematic side sectional view of an aerosol generating article according to the present invention; and

Fig. 2 shows a schematic side sectional view of another aerosol generating article according to the present invention.

The present invention will now be further described with reference to the accompanying drawing of Fig. 1, which shows a schematic side sectional view of an aerosol generating article according to the present invention.

The aerosol-generating article 10 shown in Fig. 1 comprises a rod 12 of an aerosol-generating substrate 12 and a downstream section 114 at a location downstream of the rod 12 of the aerosol-generating substrate. In addition, the aerosol-generating article 10 comprises an upstream section 16 at a location upstream of the rod 12 of the aerosol-generating substrate. Thus, the aerosol-generating article 10 extends from an upstream or distal end 18 to a downstream or mouth end 20.

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

The downstream section 14 comprises a support element 22 located downstream of the aerosol-generating substrate rod 12 immediately after it, wherein the support element 22 has a longitudinal alignment with the rod 12. In the embodiment of Fig. 1, the upstream end of the support element 18 is adjacent to the downstream end of the aerosol-generating substrate rod 12. In addition, the downstream section 14 comprises an aerosol cooling element 24 located downstream of the support element 22 immediately after it, wherein the aerosol cooling element 24 has a longitudinal alignment with the rod 12 and the support element 22. In the embodiment of Fig. 1, the upstream end of the aerosol cooling element 24 is adjacent to the downstream end of the support element 22.

As will be understood from the following description, the support member 22 and the aerosol cooling member 24 together form an intermediate hollow section 50 of the aerosol-generating article 10. In general, the intermediate hollow section 50 does not make a significant contribution to the overall RTD of the aerosol-generating article. The RTD of the intermediate hollow section 26 as a whole is substantially 0 millimeters H ₂ O.

The support element 22 comprises a first hollow tubular segment 26. The first hollow tubular segment 26 is provided in the form of a hollow cylindrical tube made of cellulose acetate. The first hollow tubular segment 26 forms an internal cavity 28, which extends over the entire distance from the upstream end 30 of the first hollow tubular segment to the downstream end 32 of the first hollow tubular segment 20. The internal cavity 28 is substantially empty, and therefore a substantially unlimited flow of air along the internal cavity 28 is possible. The first hollow tubular segment 26 and, as a result, the support element 22 do not make a significant contribution to the overall RTD of the aerosol-generating article 10. More specifically, the RTD of the first hollow tubular segment 26 (which is essentially the RTD of the support element 22) is essentially 0 millimeters H ₂ O.

The first hollow tubular segment 26 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 tubular segment 26 is approximately 2.67 millimeters.

The aerosol cooling element 24 comprises a second hollow tubular segment 34. The second hollow tubular segment 34 is provided in the form of a hollow cylindrical tube made of acetyl cellulose. The second hollow tubular segment 34 defines an internal cavity 36 that extends over the entire distance from the upstream end 38 of the second hollow tubular segment to the downstream end 40 of the second hollow tubular segment 34. The internal cavity 36 is substantially empty, and therefore a substantially unlimited flow of air along the internal cavity 36 is possible. The second hollow tubular segment 28 and, as a result, the aerosol cooling element 24 do not make a significant contribution to the overall RTD of the aerosol generating article 10. More specifically, the RTD of the second hollow tubular segment 34 (which is essentially the RTD of the aerosol cooling element 24) is essentially 0 millimeters H ₂ O.

The second hollow tubular segment 34 has a length of approximately 8 millimeters, an outer diameter of approximately 7.25 millimeters and an inner diameter ( _DSTS ) of approximately 3.25 millimeters. Thus, the thickness of the peripheral wall of the second hollow tubular segment 34 is approximately 2 millimeters. Thus, the ratio between the inner diameter ( _DSTS ) of the first hollow tubular segment 26 and the inner diameter ( _DSTS ) of the second hollow tubular segment 34 is approximately 0.75.

The aerosol generating article 10 comprises a ventilation zone 60 provided at a location along the second hollow tubular segment 34. More specifically, the ventilation zone is provided at a distance of approximately 2 millimeters from the upstream end of the second hollow tubular segment 34. The ventilation level of the aerosol generating article 10 is approximately 25 percent.

In the embodiment of Fig. 1, the downstream section 14 further comprises a mouthpiece element 42 at a location downstream of the intermediate hollow section 50. More specifically, the mouthpiece element 42 is located downstream of the aerosol cooling element 24 immediately after it. As shown in the drawing of Fig. 1, the upstream end of the mouthpiece element 42 adjoins the downstream end 40 of the aerosol cooling element 18.

The mouthpiece element 42 is provided in the form of a cylindrical plug made of low-density acetyl cellulose.

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 H ₂ O.

Rod 12 contains an aerosol generating substrate of one of the types described above.

The rod 12 of the aerosol generating substrate has an outer diameter of approximately 7.25 millimeters and a length of approximately 12 millimeters.

The aerosol-generating article 10 further comprises an elongated current collector 44 inside the rod 12 of the aerosol-generating substrate. More specifically, the current collector 44 is arranged substantially longitudinally inside the aerosol-generating substrate in such a way that it is approximately parallel to the longitudinal direction of the rod 12. As shown in the drawing of Fig. 1, the current collector 44 is arranged in a radially central position inside the rod and extends substantially along the longitudinal axis of the rod 12.

The current collector 44 extends the entire distance from the upstream end to the downstream end of the rod 12. In fact, the current collector 44 has substantially the same length as the rod 12 of the aerosol-generating substrate.

In the embodiment of Fig. 1, the current collector 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 located upstream of the rod 12 of the aerosol-generating substrate immediately before it, wherein the upstream element 46 has a longitudinal alignment with the rod 12. In the embodiment of Fig. 1, the downstream end of the upstream element 46 adjoins the upstream end of the rod 12 of the aerosol-generating substrate. This advantageously prevents the current collector 44 from shifting. In addition, this ensures that the consumer is not accidentally in contact with the heated current collector 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. The upstream element 46 has a length of approximately 5 millimeters. The RTD of the upstream element 46 is approximately 30 millimeters H ₂ O.

The aerosol generating article 110 shown in Fig. 2 has substantially the same general structure as the aerosol generating article 10 of Fig. 1, and will be described below only to the extent that it differs from the aerosol generating article 10.

As shown in Fig. 2, the aerosol-generating article 110 comprises a rod 12 of an aerosol-generating substrate and a modified downstream section 14 at a location downstream of the rod 12 of the aerosol-generating substrate. In addition, the aerosol-generating article 10 comprises an upstream section 16 at a location upstream of the rod 12 of the aerosol-generating substrate.

Similar to the downstream section 14 of the aerosol-generating article 10, the modified downstream section 114 of the aerosol-generating article 110 comprises a support element 22 located downstream of the rod 12 of the aerosol-generating substrate immediately thereafter, wherein the support element 22 has a longitudinal alignment with the rod 12, and the upstream end of the support element 22 is adjacent to the downstream end of the rod 12 of the aerosol-generating substrate.

In addition, the modified downstream section 114 comprises an aerosol cooling element 124 located downstream of the support element 22 immediately after it, wherein the aerosol cooling element 124 has a longitudinal alignment with the rod 12 and the support element 22. More specifically, the upstream end of the aerosol cooling element 124 is adjacent to the downstream end of the support element 22.

In contrast to the downstream section 14 of the aerosol-generating article 10, the aerosol cooling element 124 in the modified downstream section 114 comprises a plurality of longitudinally extending channels that provide low or substantially zero resistance to air flow through the rod. More specifically, the aerosol cooling element 124 is made of a 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 illustrated in Fig. 2, the aerosol cooling element 124 is provided in the form of a corrugated and assembled sheet of polylactic acid (PLA). The aerosol cooling element 124 has a length of approximately 8 millimeters and an outer diameter of approximately 7.25 millimeters.

Claims (22)

1. An aerosol generating article for creating an inhalable aerosol upon heating, comprising: aerosol generating substrate rod; an elongated current collector located longitudinally within the aerosol-generating substrate, wherein the current collector extends the entire distance to the downstream end of the rod of the aerosol-generating article; wherein the current collector has a thickness of 55 to 65 µm; and the ratio between the length of the current collector and the total length of the aerosol generating product is from 0.2 to 0.35. 2. An aerosol-generating article according to claim 1, wherein the current collector has a thickness of 57 to 63 µm. 3. An aerosol-generating article according to any of the preceding claims, wherein the ratio between the length of the current collector and the total length of the aerosol-generating article is from 0.24 to 0.32. 4. An aerosol generating article according to any of the preceding claims, wherein the current collector has a length of at least 2 mm. 5. An aerosol-generating article according to any of the preceding claims, wherein the current collector has a width less than or equal to 6 mm. 6. An aerosol-generating article according to any of the preceding paragraphs, further comprising: a downstream section at a location downstream of the aerosol-generating substrate rod, said downstream section comprising an aerosol cooling element arranged in longitudinal alignment with the aerosol-generating substrate rod and comprising a hollow tubular segment that defines a cavity extending the entire distance from an upstream end of the hollow tubular segment to a downstream end of the hollow tubular segment; and ventilation zone in a location along the hollow tubular segment. 7. An aerosol generating article according to claim 6, wherein the distance between the ventilation zone and the downstream end of the current collector is at least 2 mm. 8. An aerosol generating article according to claim 6 or 7, wherein the distance between the ventilation zone and the downstream end of the current collector is less than 20 millimetres or equal to 20 mm. 9. An aerosol generating article according to any one of paragraphs 6-8, wherein the hollow tubular segment has a length of less than 10 mm. 10. An aerosol generating article according to any one of paragraphs 6-9, having a ventilation level of at least 10%. 11. An aerosol generating article according to any one of paragraphs 6-10, having a ventilation level of less than 40%. 12. An aerosol generating article according to any of the preceding claims, wherein the downstream section further comprises a mouthpiece element located downstream of the aerosol cooling element. 13. The aerosol generating article of claim 12, wherein the resistance to draw (RTD) of the mouthpiece element is less than 15 mm H2O. 14. An aerosol-generating article according to any of the preceding claims, further comprising an upstream section at a location upstream of the aerosol-generating substrate rod, wherein said upstream section comprises an upstream element that is upstream of the aerosol-generating substrate rod immediately upstream thereof. 15. The aerosol generating article of claim 14, wherein the RTD of the upstream element is less than 40 mm H2O. 16. An aerosol-generating article according to any of the preceding claims, characterized in that the aerosol-generating substrate comprises a gel composition that comprises an alkaloid compound or a cannabinoid compound, or both an alkaloid compound and a cannabinoid compound, or wherein the aerosol-generating substrate comprises homogenized plant material containing particles of a non-tobacco plant flavoring substance.

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