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WO2025011989A1 - Élément amont amélioré - Google Patents

Élément amont amélioré Download PDF

Info

Publication number
WO2025011989A1
WO2025011989A1 PCT/EP2024/068405 EP2024068405W WO2025011989A1 WO 2025011989 A1 WO2025011989 A1 WO 2025011989A1 EP 2024068405 W EP2024068405 W EP 2024068405W WO 2025011989 A1 WO2025011989 A1 WO 2025011989A1
Authority
WO
WIPO (PCT)
Prior art keywords
woven material
upstream element
aerosol
micrometres
airlaid
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
PCT/EP2024/068405
Other languages
English (en)
Inventor
Stefanos PAPAKYRILLOU
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Philip Morris Products SA
Original Assignee
Philip Morris Products SA
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Philip Morris Products SA filed Critical Philip Morris Products SA
Publication of WO2025011989A1 publication Critical patent/WO2025011989A1/fr
Pending legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24D—CIGARS; CIGARETTES; TOBACCO SMOKE FILTERS; MOUTHPIECES FOR CIGARS OR CIGARETTES; MANUFACTURE OF TOBACCO SMOKE FILTERS OR MOUTHPIECES
    • A24D1/00—Cigars; Cigarettes
    • A24D1/20—Cigarettes specially adapted for simulated smoking devices
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24D—CIGARS; CIGARETTES; TOBACCO SMOKE FILTERS; MOUTHPIECES FOR CIGARS OR CIGARETTES; MANUFACTURE OF TOBACCO SMOKE FILTERS OR MOUTHPIECES
    • A24D3/00—Tobacco smoke filters, e.g. filter-tips, filtering inserts; Filters specially adapted for simulated smoking devices; Mouthpieces for cigars or cigarettes
    • A24D3/06—Use of materials for tobacco smoke filters
    • A24D3/062—Use of materials for tobacco smoke filters characterised by structural features
    • A24D3/063—Use of materials for tobacco smoke filters characterised by structural features of the fibers
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24D—CIGARS; CIGARETTES; TOBACCO SMOKE FILTERS; MOUTHPIECES FOR CIGARS OR CIGARETTES; MANUFACTURE OF TOBACCO SMOKE FILTERS OR MOUTHPIECES
    • A24D3/00—Tobacco smoke filters, e.g. filter-tips, filtering inserts; Filters specially adapted for simulated smoking devices; Mouthpieces for cigars or cigarettes
    • A24D3/06—Use of materials for tobacco smoke filters
    • A24D3/067—Use of materials for tobacco smoke filters characterised by functional properties
    • A24D3/068—Biodegradable or disintegrable
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24D—CIGARS; CIGARETTES; TOBACCO SMOKE FILTERS; MOUTHPIECES FOR CIGARS OR CIGARETTES; MANUFACTURE OF TOBACCO SMOKE FILTERS OR MOUTHPIECES
    • A24D3/00—Tobacco smoke filters, e.g. filter-tips, filtering inserts; Filters specially adapted for simulated smoking devices; Mouthpieces for cigars or cigarettes
    • A24D3/06—Use of materials for tobacco smoke filters
    • A24D3/08—Use of materials for tobacco smoke filters of organic materials as carrier or major constituent
    • A24D3/10—Use of materials for tobacco smoke filters of organic materials as carrier or major constituent of cellulose or cellulose derivatives
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24D—CIGARS; CIGARETTES; TOBACCO SMOKE FILTERS; MOUTHPIECES FOR CIGARS OR CIGARETTES; MANUFACTURE OF TOBACCO SMOKE FILTERS OR MOUTHPIECES
    • A24D3/00—Tobacco smoke filters, e.g. filter-tips, filtering inserts; Filters specially adapted for simulated smoking devices; Mouthpieces for cigars or cigarettes
    • A24D3/17—Filters specially adapted for simulated smoking devices

Definitions

  • the present disclosure relates to an upstream element for an aerosol-generating article.
  • the present disclosure also relates to a method of manufacturing an upstream element.
  • the present disclosure also relates to an aerosol-generating article comprising an aerosol-generating substrate for generating an inhalable aerosol upon heating and an aerosol-generating device configured to heat the aerosol-generating substrate of the aerosol-generating article.
  • Aerosol-generating articles in which an aerosol-generating substrate comprising aerosolgenerating material, such as a tobacco-containing material, is heated rather than combusted are known in the art.
  • an aerosol is generated by the transfer of heat from a heat source to a physically separate aerosol-generating substrate.
  • volatile compounds are released from the aerosol-generating substrate by heat transfer from the heat source to the aerosol-generating substrate and are entrained in air drawn through the aerosolgenerating article. As the released compounds cool, they condense to form an aerosol that is inhaled by the user.
  • heated aerosol-generating article commonly referred to as a heat-not- burn tobacco product or heated tobacco product, comprises a solid aerosol-generating substrate comprising tobacco material, which is heated to produce an inhalable aerosol.
  • a number of handheld aerosol-generating devices configured to heat aerosol-generating substrates of heated aerosol-generating articles are known in the art. These include electrically- operated aerosol-generating devices in which an aerosol is generated by the transfer of heat from one or more electrical heating elements of the aerosol-generating device to the aerosolgenerating substrate of the heated aerosol-generating article.
  • Known handheld electrically operated aerosol-generating devices typically comprise a battery, control electronics and one or more electrical heating elements for heating the aerosol-generating substrate of a heated aerosolgenerating article designed specifically for use with the aerosol-generating device.
  • Some known electrically heated aerosol-generating devices comprise an internal heating element that is configured to be inserted into the aerosol-generating substrate of a heated aerosol-generating article.
  • WO 2013/098410 A2 discloses an aerosol-generating system comprising an aerosol-generating article and an electrically-operated aerosol-generating device comprising a heating element in the form of a blade that is inserted into the aerosolgenerating substrate of the aerosol-generating article.
  • WO 2020/115151 A1 discloses an aerosol-generating system comprising an aerosol-generating article and an electrically-operated aerosol-generating device comprising an external heating element that circumscribes the periphery of the aerosolgenerating article.
  • WO 2015/176898 A1 discloses an aerosol-generating system comprising an aerosol-generating article comprising an elongate susceptor in thermal contact with the aerosol-generating substrate and an electrically-operated aerosol-generating device having an inductor for heating the aerosol-generating substrate.
  • the fluctuating or alternating electromagnetic field produced by the inductor induces eddy currents in the susceptor, causing the susceptor to heat up as a result of one or both of resistive losses (Joule heating) and, where the susceptor is magnetic, hysteresis loses. Heat generated in the susceptor is transferred to the aerosol-generating substrate by conduction.
  • the aerosol-generating substrate of an aerosol-generating article may absorb water from the air, for example, during storage of the aerosol-generating article.
  • the aerosol-generating substrate may absorb water from the air until an equilibrium point is reached, at which point the water content of the aerosol-generating substrate may be equal to the relative humidity of the environment.
  • Heating of the aerosol-generating substrate during use of the aerosol-generating article may result in evaporation of the absorbed water, for example, prior to the evaporation of nicotine and glycerine in the aerosol-generating substrate.
  • the resulting water vapour may carry a significant amount of energy and may increase the temperature of aerosol delivered to a user. This may result in an uncomfortable sensory experience for the user during at least the initial puffs by the user. This phenomenon is referred to as ‘warm aerosol perception’ and may be particularly problematic in warm and humid environments. In some instances, warm aerosol perception may deter a user from using the aerosol-generating article.
  • Aerosol-generating articles comprising an upstream element are known.
  • Some known aerosol-generating articles comprise an upstream element in the form of a plug of cellulose acetate tow.
  • the present disclosure relates to an upstream element for an aerosol-generating article.
  • the upstream element may be formed of a non-woven material.
  • the upstream element may be formed of an airlaid non-woven material.
  • an upstream element for an aerosol-generating article wherein the upstream element is formed of an airlaid non-woven material.
  • an upstream element from an airlaid non-woven material enables the manufacture of the upstream element from more sustainable, for example, natural or biodegradable materials, without compromising on the functional and mechanical properties of the upstream element.
  • the airlaid non-woven material may comprise cellulose fibres.
  • the airlaid non-woven material may comprise at least 90 percent by weight cellulose.
  • the airlaid non-woven material may comprise at least 95 percent by weight cellulose.
  • the airlaid non-woven material may comprise at least 99 percent by weight cellulose.
  • the airlaid non-woven material may comprise 100 percent by weight cellulose.
  • the upstream element is formed from a more sustainable material without compromising the functional properties or manufacturability of the upstream element.
  • the airlaid non-woven material may comprise a fibre web material.
  • the airlaid non-woven material may comprise bonded webs.
  • the bonded webs may be high pressure bonded webs.
  • the bonded webs may be hydroentangled bonded webs.
  • the inclusion of bonded webs enables the manufacture of an upstream element having the required functional properties, for example the hardness required for stick insertion, for example to ensure a consumable’s resilience when inserted into an aerosolgenerating device or into a stick’s final configuration during a combining process.
  • the airlaid non-woven material may have a weight per surface area of at least 15 grams per metre squared.
  • the airlaid non-woven material may have a weight per surface area of at least 30 grams per metre squared.
  • the airlaid non-woven material may have a weight per surface area of at least 50 grams per metre squared.
  • the airlaid non-woven material may have a weight per surface area of at least 60 grams per metre squared.
  • the airlaid non-woven material may have a weight per surface area of up to 600 grams per metre squared.
  • the airlaid non-woven material may have a weight per surface area of up to 200 grams per metre squared.
  • the airlaid non-woven material may have a weight per surface area of up to 70 grams per metre squared.
  • the airlaid non-woven material may have a weight per surface areas between 15 grams per metre squared and 600 grams per metre squared.
  • the airlaid non-woven material may have a weight per surface area of between 30 grams per metre squared and 200 grams per metre squared.
  • the airlaid non-woven material may have a weight per surface area of between 60 grams per metre squared and 180 grams per metre squared.
  • the airlaid non-woven material may have a weight per surface area of 62 grams per metre squared.
  • the airlaid non-woven material may have a weight per surface area of 170 grams per metre squared.
  • the area density of the airlaid non-woven material enables the manufacture of an upstream element having the required functional properties, for example to ensure that the required pressure drop is achieved, for example the pressure drop needed to ensure proper aerosol delivery.
  • the airlaid non-woven material may be a sheet.
  • the sheet may have a bobbin width of at least 400 millimetres.
  • the sheet may have a bobbin width of up to 500 millimetres.
  • the sheet may have a bobbin width of between 400 millimetres and 500 millimetres.
  • the sheet may have a bobbin width of at least 120 millimetres.
  • the sheet may have a bobbin width of up to 210 millimetres.
  • the sheet may have a bobbin width of between 120 millimetres and 210 millimetres.
  • the bobbin width is selected to ensure the manufacture of an upstream element having the required functional properties, for example to ensure that the required pressure drop is achieved, for example the pressure drop needed to ensure proper aerosol delivery.
  • the upstream element may be formed of an airlaid non-woven material.
  • an upstream element for an aerosol-generating article wherein the upstream element is formed of an airlaid non-woven material.
  • an upstream element from an airlaid non-woven material enables the manufacture of the upstream element from more sustainable, for example, natural or biodegradable materials, without compromising on the functional and mechanical properties of the upstream element.
  • the airlaid non-woven material may comprise cellulose fibres.
  • the airlaid non-woven material may comprise at least 90 percent by weight cellulose.
  • the airlaid non-woven material may comprise at least 95 percent by weight cellulose.
  • the airlaid non-woven material may comprise at least 99 percent by weight cellulose.
  • the airlaid non-woven material may comprise 100 percent by weight cellulose.
  • the upstream element is formed from a more sustainable material without compromising the functional properties or manufacturability of the upstream element.
  • the airlaid non-woven material may comprise a fibre web material.
  • the airlaid non-woven material may comprise bonded webs.
  • the bonded webs may be high pressure bonded webs.
  • the bonded webs may be hydroentangled bonded webs.
  • the inclusion of bonded webs enables the manufacture of an upstream element having the required functional properties, for example the hardness required for stick insertion, for example to ensure a consumable’s resilience when inserted into an aerosolgenerating device or into a stick’s final configuration during a combining process.
  • the airlaid non-woven material may have a weight per surface area of at least 15 grams per metre squared.
  • the airlaid non-woven material may have a weight per surface area of at least 30 grams per metre squared.
  • the airlaid non-woven material may have a weight per surface area of at least 50 grams per metre squared.
  • the airlaid non-woven material may have a weight per surface area of at least 60 grams per metre squared.
  • the airlaid non-woven material may have a weight per surface area of up to 600 grams per metre squared.
  • the airlaid non-woven material may have a weight per surface area of up to 200 grams per metre squared.
  • the airlaid non-woven material may have a weight per surface area of up to 70 grams per metre squared.
  • the airlaid non-woven material may have a weight per surface areas between 15 grams per metre squared and 600 grams per metre squared.
  • the airlaid non-woven material may have a weight per surface area of between 30 grams per metre squared and 200 grams per metre squared.
  • the airlaid non-woven material may have a weight per surface area of between 60 grams per metre squared and 180 grams per metre squared.
  • the airlaid non-woven material may have a weight per surface area of 62 grams per metre squared.
  • the airlaid non-woven material may have a weight per surface area of 170 grams per metre squared.
  • the area density of the airlaid non-woven material enables the manufacture of an upstream element having the required functional properties, for example to ensure that the required pressure drop is achieved, for example the pressure drop needed to ensure proper aerosol delivery.
  • the airlaid non-woven material may be a sheet.
  • the sheet may have a bobbin width of at least 400 millimetres.
  • the sheet may have a bobbin width of up to 500 millimetres.
  • the sheet may have a bobbin width of between 400 millimetres and 500 millimetres.
  • the sheet may have a bobbin width of at least 120 millimetres.
  • the sheet may have a bobbin width of up to 210 millimetres.
  • the sheet may have a bobbin width of between 120 millimetres and 210 millimetres.
  • the bobbin width is selected to ensure the manufacture of an upstream element having the required functional properties, for example to ensure that the required pressure drop is achieved, for example the pressure drop needed to ensure proper aerosol delivery.
  • the upstream element may be formed of a wetlaid non-woven material.
  • an upstream element for an aerosol-generating article wherein the upstream element is formed of a wetlaid non-woven material.
  • an upstream element from a wetlaid non-woven material enables the manufacture of the upstream element from more sustainable, for example, natural or biodegradable materials, without compromising on the functional and mechanical properties of the upstream element.
  • the wetlaid non-woven material may comprise cellulose fibres.
  • the wetlaid non-woven material may comprise at least 90 percent by weight cellulose.
  • the wetlaid non-woven material may comprise at least 95 percent by weight cellulose.
  • the wetlaid non-woven material may comprise at least 99 percent by weight cellulose.
  • the wetlaid non-woven material may comprise 100 percent by weight cellulose.
  • the upstream element is formed from a more sustainable material without compromising the functional properties or manufacturability of the upstream element.
  • the wetlaid non-woven material may comprise a fibre web material.
  • the wetlaid non-woven material may comprise bonded webs.
  • the bonded webs may be high pressure bonded webs.
  • the bonded webs may be hydroentangled bonded webs.
  • the inclusion of bonded webs enables the manufacture of an upstream element having the required functional properties, for example the hardness required for stick insertion, for example to ensure a consumable’s resilience when inserted into an aerosolgenerating device or into a stick’s final configuration during a combining process.
  • the wetlaid non-woven material may have a weight per surface area of at least 15 grams per metre squared.
  • the airlaid non-woven material may have a weight per surface area of at least 30 grams per metre squared.
  • the wetlaid non-woven material may have a weight per surface area of at least 50 grams per metre squared.
  • the wetlaid non-woven material may have a weight per surface area of at least 60 grams per metre squared.
  • the wetlaid non-woven material may have a weight per surface area of up to 600 grams per metre squared.
  • the wetlaid non-woven material may have a weight per surface area of up to 200 grams per metre squared.
  • the wetlaid non-woven material may have a weight per surface area of up to 70 grams per metre squared.
  • the wetlaid non-woven material may have a weight per surface areas between 15 grams per metre squared and 600 grams per metre squared.
  • the wetaid non-woven material may have a weight per surface area of between 30 grams per metre squared and 200 grams per metre squared.
  • the wetlaid non-woven material may have a weight per surface area of between 60 grams per metre squared and 180 grams per metre squared.
  • the wetlaid non-woven material may have a weight per surface area of 62 grams per metre squared.
  • the wetlaid non-woven material may have a weight per surface area of 170 grams per metre squared.
  • the area density of the wetlaid non-woven material enables the manufacture of an upstream element having the required functional properties, for example to ensure that the required pressure drop is achieved, for example the pressure drop needed to ensure proper aerosol delivery.
  • the wetlaid non-woven material may be a sheet.
  • the sheet may have a bobbin width of at least 400 millimetres.
  • the sheet may have a bobbin width of up to 500 millimetres.
  • the sheet may have a bobbin width of between 400 millimetres and 500 millimetres.
  • the sheet may have a bobbin width of at least 120 millimetres.
  • the sheet may have a bobbin width of up to 210 millimetres.
  • the sheet may have a bobbin width of between 120 millimetres and 210 millimetres.
  • the bobbin width is selected to ensure the manufacture of an upstream element having the required functional properties, for example to ensure that the required pressure drop is achieved, for example the pressure drop needed to ensure proper aerosol delivery.
  • the airlaid non-woven material or the wetlaid non-woven material may be a crimped nonwoven material.
  • crimping the airlaid or wetlaid non-woven material improves the manufacturability of an upstream element.
  • the crimped non-woven material prevents expansion of the upstream element, which might unseal a plug and/or break the consumable wrapping.
  • the crimped non-woven material may also ensure that the upstream element has the required particle filtering properties, for example that it does not include air tight regions and/or regions having large holes.
  • the upstream element may comprise a particle retention feature.
  • the particle retention feature of the upstream element helps to ensure that particles are retained within an aerosol-generating article.
  • the particle retention feature may include the plurality of longitudinal folds.
  • the crimped non-woven material may include a longitudinal fold.
  • the crimped non-woven material may include a plurality of longitudinal folds. Each longitudinal fold may be spaced from its adjacent longitudinal fold or folds by a distance. The distance between adjacent longitudinal folds may be less than 1000 micrometres. The distance between adjacent longitudinal folds may be less than 750 micrometres. The distance between adjacent longitudinal folds may be less than 500 micrometres.
  • the distance between adjacent longitudinal folds may be at least 25 micrometres.
  • the distance between adjacent longitudinal folds may be at least 50 micrometres.
  • the distance between adjacent longitudinal folds may be at least 100 micrometres.
  • the distance between adjacent longitudinal folds may be between 25 micrometres and 1000 micrometres.
  • the distance between adjacent longitudinal folds may be between 25 micrometres and 750 micrometres.
  • the distance between adjacent longitudinal folds may be between 25 micrometres and 500 micrometres.
  • the distance between adjacent longitudinal folds may be between 50 micrometres and 1000 micrometres.
  • the distance between adjacent longitudinal folds may be between 50 micrometres and 750 micrometres.
  • the distance between adjacent longitudinal folds may be between 50 micrometres and 500 micrometres.
  • the distance between adjacent longitudinal folds may be between 100 micrometres and 1000 micrometres.
  • the distance between adjacent longitudinal folds may be between 100 micrometres and 750 micrometres.
  • the distance between adjacent longitudinal folds may be between 100 micrometres and 500 micrometres.
  • the distance between adjacent longitudinal folds may be less than the particle size of the particle of aerosol-generating material.
  • the distance between adjacent longitudinal folds is optimised in order to ensure that the particle retention properties of the upstream element are adequate.
  • the or each longitudinal fold may have a height.
  • the height of the or each longitudinal fold may correspond to the distance between adjacent longitudinal folds.
  • the height of the or each longitudinal fold may be less than 1000 micrometres.
  • the height of the or each longitudinal fold may be less than 750 micrometres.
  • the height of the or each longitudinal fold may be less than 500 micrometres.
  • the height of the or each longitudinal fold may be at least 25 micrometres.
  • the height of the or each longitudinal fold may be at least 50 micrometres.
  • the height of the or each longitudinal fold may be at least 100 micrometres.
  • the height of the or each longitudinal fold may be between 25 micrometres and 1000 micrometres.
  • the height of the or each longitudinal fold may be between 25 micrometres and 750 micrometres.
  • the height of the or each longitudinal fold may be between 25 micrometres and 500 micrometres.
  • the height of the or each longitudinal fold may be between 50 micrometres and 1000 micrometres.
  • the height of the or each longitudinal fold may be between 50 micrometres and 750 micrometres.
  • the height of the or each adjacent longitudinal fold may be between 50 micrometres and 500 micrometres.
  • the height of the or each longitudinal fold may be between 100 micrometres and 1000 micrometres.
  • the height of the or each longitudinal fold may be between 100 micrometres and 750 micrometres.
  • the height of the or each longitudinal fold may be between 100 micrometres and 500 micrometres.
  • the height of the or each longitudinal fold may be less than the particle size of the particle of aerosol-generating material.
  • the height of the or each longitudinal fold is optimised in order to ensure that the particle retention properties of the upstream element are adequate.
  • the upstream element may have a length of 5 millimetres.
  • the upstream element may have a resistance to draw of 1.53 millimetres H2O per millimetre of length of the upstream element.
  • the upstream element may have a resistance to draw of 7.65 millimetres H2O.
  • the airlaid non-woven material or the wetlaid non-woven material may have a bulk density inside the upstream element of about 0.13 milligrams per cubic millimetre.
  • the upstream element may be resistant to heat.
  • the upstream element may be resistant to shrinkage.
  • an upstream element for an aerosol-generating article comprising a non-woven material.
  • the non-woven material may be formed by an airlaying process.
  • the upstream element may be formed by an airforming process.
  • the non-woven material may be formed by a wetlaying process.
  • the upstream element may be formed by a wetlaying process.
  • an upstream element for an aerosol-generating article wherein the upstream element comprises a non-woven material, and wherein the non-woven material is formed by an airlaying process.
  • an upstream element from an airlaid non-woven material enables the manufacture of the upstream element from more sustainable, for example, natural or biodegradable materials, without compromising on the functional and mechanical properties of the upstream element.
  • an upstream element for an aerosol-generating article wherein the upstream element comprises a non-woven material, and wherein the non-woven material is formed by a wetlaying process
  • the airlaid non-woven material or the wetlaid non-woven material may comprise a fibre web material.
  • the fibre webs may be bonded by a high pressure bonding process.
  • the fibre webs may be bonded by a hydroentanglement bonding process.
  • the airlaid non-woven material or the wetlaid non-woven material may be pulled between a first roller and a second roller.
  • the first roller may have at least one outer ridge.
  • the second roller may have at least one outer groove.
  • the at least one outer ridge and the at least one outer groove may be complementary.
  • a corrugation pattern may be formed on the airlaid non-woven material.
  • the airlaid non-woven material or the wetlaid non-woven material may be pulled in a direction.
  • the airlaid non-woven material or the wetlaid non-woven material may be pulled between the first roller and the second roller in a direction.
  • the corrugation pattern may be aligned with the direction in which the airlaid non-woven material or the wetlaid non-woven material is pulled.
  • the corrugation pattern may be a longitudinal corrugation pattern.
  • the corrugation pattern may include a plurality of longitudinal folds. Each longitudinal fold may be spaced from its adjacent longitudinal fold or folds by a distance.
  • the distance between adjacent longitudinal folds may be less than 1000 micrometres.
  • the distance between adjacent longitudinal folds may be less than 750 micrometres.
  • the distance between adjacent longitudinal folds may be less than 500 micrometres.
  • the distance between adjacent longitudinal folds may be at least 25 micrometres.
  • the distance between adjacent longitudinal folds may be at least 50 micrometres.
  • the distance between adjacent longitudinal folds may be at least 100 micrometres.
  • the distance between adjacent longitudinal folds may be between 25 micrometres and 1000 micrometres.
  • the distance between adjacent longitudinal folds may be between 25 micrometres and 750 micrometres.
  • the distance between adjacent longitudinal folds may be between 25 micrometres and 500 micrometres.
  • the distance between adjacent longitudinal folds may be between 50 micrometres and 1000 micrometres.
  • the distance between adjacent longitudinal folds may be between 50 micrometres and 750 micrometres.
  • the distance between adjacent longitudinal folds may be between 50 micrometres and 500 micrometres.
  • the distance between adjacent longitudinal folds may be between 100 micrometres and 1000 micrometres.
  • the distance between adjacent longitudinal folds may be between 100 micrometres and 750 micrometres.
  • the distance between adjacent longitudinal folds may be between 100 micrometres and 500 micrometres.
  • the or each longitudinal fold may have a height.
  • the height of the or each longitudinal fold may correspond to the distance between adjacent longitudinal folds.
  • the height of the or each longitudinal fold may be less than 1000 micrometres.
  • the height of the or each longitudinal fold may be less than 750 micrometres.
  • the height of the or each longitudinal fold may be less than 500 micrometres.
  • the height of the or each longitudinal fold may be at least 25 micrometres.
  • the height of the or each longitudinal fold may be at least 50 micrometres.
  • the height of the or each longitudinal fold may be at least 100 micrometres.
  • the height of the or each longitudinal fold may be between 25 micrometres and 1000 micrometres.
  • the height of the or each longitudinal fold may be between 25 micrometres and 750 micrometres.
  • the height of the or each longitudinal fold may be between 25 micrometres and 500 micrometres.
  • the height of the or each longitudinal fold may be between 50 micrometres and 1000 micrometres.
  • the height of the or each longitudinal fold may be between 50 micrometres and 750 micrometres.
  • the height of the or each adjacent longitudinal fold may be between 50 micrometres and 500 micrometres.
  • the height of the or each longitudinal fold may be between 100 micrometres and 1000 micrometres.
  • the height of the or each longitudinal fold may be between 100 micrometres and 750 micrometres.
  • the height of the or each longitudinal fold may be between 100 micrometres and 500 micrometres.
  • the airlaid non-woven material or the wetlaid non-woven material may be subjected to one or more further processes.
  • the one or more further processes may control the distance between adjacent longitudinal folds.
  • the one or more further processes may include an embossing process.
  • the corrugated airlaid non-woven material or the corrugated wetlaid non-woven material may be pulled through a funnel device.
  • the corrugated airlaid non-woven material or the corrugated wetlaid non-woven material may be pulled through a funnel device in order to form a cylinder.
  • the cylinder may be wrapped.
  • the cylinder may be cut into one or more plugs.
  • the upstream element may be a plug.
  • the upstream element may be a front plug.
  • a method of manufacturing an upstream element may comprise airlaying a sheet of non-woven material.
  • the method may comprise forming a cylinder of the airlaid non-woven material.
  • the method may comprise wrapping the cylinder.
  • the method may be comprise cutting the cylinder into one or more plugs.
  • a method of manufacturing an upstream element comprising airlaying a sheet of non-woven material, forming a cylinder of the airlaid non-woven material, wrapping the cylinder and cutting the cylinder into one or more plugs.
  • the manufacture of an upstream element from an airlaid non-woven material enables the use of more sustainable, for example, natural or biodegradable materials, without compromising on the functional and mechanical properties of the upstream element.
  • the method may comprise crimping the airlaid non-woven material.
  • the method may comprise embossing the airlaid non-woven material.
  • a method of manufacturing an upstream element may comprise wetlaying a sheet of non-woven material.
  • the method may comprise forming a cylinder of the wetlaid non-woven material.
  • the method may comprise wrapping the cylinder.
  • the method may be comprise cutting the cylinder into one or more plugs.
  • a method of manufacturing an upstream element comprising wetlaying a sheet of non-woven material, forming a cylinder of the wetlaid non-woven material, wrapping the cylinder and cutting the cylinder into one or more plugs.
  • the manufacture of an upstream element from a wetlaid non-woven material enables the use of more sustainable, for example, natural or biodegradable materials, without compromising on the functional and mechanical properties of the upstream element.
  • the method may comprise crimping the wetlaid non-woven material.
  • the method may comprise embossing the wetlaid non-woven material.
  • an aerosol-generating article comprising an aerosol-generating substrate.
  • the aerosol-generating article may comprise an upstream element.
  • the upstream element may be an upstream element according to the preceding aspects of the invention.
  • the upstream element may be located upstream of the aerosol-generating substrate.
  • the upstream element may be the most upstream plug of the aerosol-generating article.
  • the aerosol-generating article may comprise a downstream element.
  • the downstream element may comprise one or more ventilation holes.
  • the one or more ventilation holes may be arranged around a periphery of the downstream element.
  • the one or more ventilation holes may be arranged around a circumference of the downstream element.
  • the aerosol-generating article may comprise a mouthpiece filter.
  • the aerosol-generating device may comprise an aerosol-generating article.
  • the aerosolgenerating article may be an aerosol-generating article as described in the preceding aspect of the invention.
  • the aerosol-generating device may be configured to heat the aerosol-generating substrate of the aerosol-generating article.
  • the aerosol-generating device may comprise a housing.
  • the housing may define a cavity.
  • the cavity may be configured to receive the aerosolgenerating article.
  • the formation of the upstream element from an airlaid non-woven material or a wetlaid nonwoven material for example an airlaid or a wetlaid non-woven material including a biodegradable material, e.g. cellulose, enables the inexpensive and straightforward manufacture of a more sustainable upstream element.
  • airlaid non-woven material or wetlaid non-woven materials having an optimised area density ensures that the pressure drop levels required to achieve appropriate aerosol delivery are obtained.
  • Crimping the airlaid or the wetlaid non-woven material improves the manufacturability of an upstream element.
  • the crimped airlaid or wetlaid non-woven material prevents unwanted expansion of the upstream element and thus reduces the risk of a plug being unsealed or a consumable wrapped being broken.
  • the crimped airlaid or wetlaid non-woven material also helps maintain the desired particle filtering properties of the upstream element by preventing the formation of air-tight regions or big holes in the upstream element.
  • the crimping process creates “wave-like” structures in the airlaid or wetlaid non-woven material, breaking the fibres of the airlaid or wetlaid non-woven material so that the airlaid or wetlaid non-woven material collapses on itself in random directions when compressed in the funnel device, so that different layers/segments of the airlaid or wetlaid non-woven material cannot be stuck to each other and nor can they form unexpected large holes. Accordingly, the crimping process is advantageous for enabling the creation of an airlaid or wetlaid non-woven material upstream element which appropriately blocks particles of the aerosol-generating material and which has an expected, and desirable, resistance to draw.
  • a further advantage of the upsteam element of the present invention is that the crimped airlaid or welaid non-woven upstream element is more temperature resistant than cellulose acetate. Therefore, visually, and aesthetically speaking the crimped airlaid non-woven upstream element will remain intact after heating the consumable (i.e., after a user experience).
  • the resistance to temperature is also important from an resistance to draw perspective.
  • the resistance to draw of the upstream element remains unchanged throughout the entire experience, hence preserving the crimped airlaid or wetlaid non-woven upstream element quality, properties and dimensions. Consequently, the unchanged diameter of the crimped airlaid or wetlaid nonwoven upstream element can double as cleaning tool for the internal walls of the heating cavity of an aerosol-generating device.
  • proximal As used herein, the terms ‘proximal’, ‘distal’, ‘downstream’ and ‘upstream’ are used to describe the relative positions of components, or portions of components, of the aerosolgenerating device or the aerosol-generating article in relation to the direction in which a user draws on the aerosol-generating device or the aerosol-generating article during use thereof.
  • the aerosol-generating device may comprise a mouth end through which in use an aerosol exits the aerosol-generating device and is delivered to a user.
  • the mouth end may also be referred to as the proximal end.
  • a user draws on the proximal or mouth end of the aerosol-generating device in order to inhale an aerosol generated by the aerosol-generating device.
  • a user may directly draw on an aerosolgenerating article inserted into an opening at the proximal end of the aerosol-generating device. In this case, the user preferably draws on the front plug of the aerosol-generating article.
  • the opening at the proximal end of the aerosol-generating device may be an opening of the cavity.
  • the cavity may be configured to receive the aerosol-generating article.
  • the aerosol-generating device comprises a distal end opposed to the proximal or mouth end.
  • the proximal or mouth end of the aerosol-generating device may also be referred to as the downstream end and the distal end of the aerosol-generating device may also be referred to as the upstream end.
  • Components, or portions of components, of the aerosol-generating device may be described as being upstream or downstream of one another based on their relative positions between the proximal, downstream or mouth end and the distal or upstream end of the aerosol-generating device.
  • an ‘aerosol-generating device’ relates to a device that interacts with an aerosol-forming substrate to generate an aerosol.
  • the aerosol-forming substrate may be part of an aerosol-generating article, for example part of a smoking article.
  • An aerosol-generating device may be a smoking device that interacts with an aerosol-forming substrate of an aerosolgenerating article to generate an aerosol that is directly inhalable into a user’s lungs thorough the user's mouth.
  • An aerosol-generating device may be a holder.
  • the device may be an electrically heated smoking device.
  • the aerosol-generating device may comprise a housing, electric circuitry, a power supply, a heating chamber and a heating element.
  • the term ‘smoking’ with reference to a device, article, system, substrate, or otherwise does not refer to conventional smoking in which an aerosol-forming substrate is fully or at least partially combusted.
  • the aerosol-generating device of the present invention is arranged to heat the aerosol-forming substrate to a temperature below a combustion temperature of the aerosol-forming substrate, but at or above a temperature at which one or more volatile compounds of the aerosol-forming substrate are released to form an inhalable aerosol.
  • the aerosol-generating device may comprise electric circuitry.
  • the electric circuitry may comprise a microprocessor, which may be a programmable microprocessor.
  • the microprocessor may be part of a controller.
  • the electric circuitry may comprise further electronic components.
  • the electric circuitry may be configured to regulate a supply of power to the heating element. Power may be supplied to the heating element continuously following activation of the aerosolgenerating device or may be supplied intermittently, such as on a puff-by-puff basis. The power may be supplied to the heating element in the form of pulses of electrical current.
  • the electric circuitry may be configured to monitor the electrical resistance of the heating element, and preferably to control the supply of power to the heating element dependent on the electrical resistance of the heating element.
  • the aerosol-generating device may comprise a power supply, typically a battery, within a main body of the aerosol-generating device.
  • the power supply is a Lithium- ion battery.
  • the power supply may be a Nickel-metal hydride battery, a Nickel cadmium battery, or a Lithium based battery, for example a Lithium-Cobalt, a Lithium-lron- Phosphate, Lithium Titanate or a Lithium-Polymer battery.
  • the power supply may be another form of charge storage device such as a capacitor.
  • the power supply may require recharging and may have a capacity that enables to store enough energy for one or more usage experiences; for example, the power supply may have sufficient capacity to continuously generate aerosol for a period of around six minutes or for a period of a multiple of six minutes. In another example, the power supply may have sufficient capacity to provide a predetermined number of puffs or discrete activations of the heating element.
  • the cavity of the aerosol-generating device may have an open end into which the aerosolgenerating article is inserted.
  • the open end may be a proximal end.
  • the cavity may have a closed end opposite the open end.
  • the closed end may be the base of the cavity.
  • the closed end may be closed except for the provision of air apertures arranged in the base.
  • the base of the cavity may be flat.
  • the base of the cavity may be circular.
  • the base of the cavity may be arranged upstream of the cavity.
  • the open end may be arranged downstream of the cavity.
  • the cavity may have an elongate extension.
  • the cavity may have a longitudinal central axis.
  • a longitudinal direction may be the direction extending between the open and closed ends along the longitudinal central axis.
  • the longitudinal central axis of the cavity may be parallel to the longitudinal axis of the aerosol-generating device.
  • the cavity may be configured as a heating chamber.
  • the cavity may have a cylindrical shape.
  • the cavity may have a hollow cylindrical shape.
  • the cavity may have a shape corresponding to the shape of the aerosol-generating article to be received in the cavity.
  • the cavity may have a circular cross-section.
  • the cavity may have an elliptical or rectangular crosssection.
  • the cavity may have an inner diameter corresponding to the outer diameter of the aerosol-generating article.
  • An airflow channel may run through the cavity. Ambient air may be drawn into the aerosolgenerating device, into the cavity and towards the user through the airflow channel. Downstream of the cavity, a mouthpiece may be arranged or a user may directly draw on the aerosolgenerating article. The airflow channel may extend through the mouthpiece.
  • the heating element may comprise an electrically resistive material.
  • Suitable electrically resistive materials include but are not limited to: semiconductors such as doped ceramics, electrically "conductive" ceramics (such as, for example, molybdenum disilicide), carbon, graphite, metals, metal alloys and composite materials made of a ceramic material and a metallic material.
  • Such composite materials may comprise doped or undoped ceramics.
  • suitable doped ceramics include doped silicon carbides.
  • suitable metals include titanium, zirconium, tantalum platinum, gold and silver.
  • suitable metal alloys include stainless steel, nickel-, cobalt-, chromium-, aluminium- titanium- zirconium-, hafnium-, niobium-, molybdenum-, tantalum-, tungsten-, tin-, gallium-, manganese-, gold- and iron-containing alloys, and super-alloys based on nickel, iron, cobalt, stainless steel, Timetai® and iron-manganese-aluminium based alloys.
  • the electrically resistive material may optionally be embedded in, encapsulated or coated with an insulating material or vice-versa, depending on the kinetics of energy transfer and the external physicochemical properties required.
  • the heating element may be part of an aerosol-generating device.
  • the aerosol-generating device may comprise an internal heating element or an external heating element, or both internal and external heating elements, where "internal” and “external” refer to the aerosol-forming substrate.
  • An internal heating element may take any suitable form.
  • an internal heating element may take the form of a heating blade.
  • the internal heater may take the form of a casing or substrate having different electro-conductive portions, or an electrically resistive metallic tube.
  • the internal heating element may be one or more heating needles or rods that run through the center of the aerosol-forming substrate.
  • the internal heating element may be deposited in or on a rigid carrier material.
  • the electrically resistive heating element may be formed using a metal having a defined relationship between temperature and resistivity.
  • the metal may be formed as a track on a suitable insulating material, such as ceramic material, and then sandwiched in another insulating material, such as a glass. Heaters formed in this manner may be used to both heat and monitor the temperature of the heating elements during operation.
  • An external heating element may take any suitable form.
  • an external heating element may take the form of one or more flexible heating foils on a dielectric substrate, such as polyimide.
  • the flexible heating foils can be shaped to conform to the perimeter of the substrate receiving cavity.
  • an external heating element may take the form of a metallic grid or grids, a flexible printed circuit board, a molded interconnect device (MID), ceramic heater, flexible carbon fibre heater or may be formed using a coating technique, such as plasma vapour deposition, on a suitable shaped substrate.
  • An external heating element may also be formed using a metal having a defined relationship between temperature and resistivity. In such an exemplary device, the metal may be formed as a track between two layers of suitable insulating materials. An external heating element formed in this manner may be used to both heat and monitor the temperature of the external heating element during operation.
  • the heating element may be configured as an induction heating element.
  • the induction heating element may comprise an induction coil and a susceptor.
  • a susceptor is a material that is capable of generating heat, when penetrated by an alternating magnetic field. When located in an alternating magnetic field. If the susceptor is conductive, then typically eddy currents are induced by the alternating magnetic field. If the susceptor is magnetic, then typically another effect that contributes to the heating is commonly referred to hysteresis losses. Hysteresis losses occur mainly due to the movement of the magnetic domain blocks within the susceptor, because the magnetic orientation of these will align with the magnetic induction field, which alternates.
  • hysteresis losses Another effect contributing to the hysteresis loss is when the magnetic domains will grow or shrink within the susceptor.
  • the susceptor is both magnetic and electrically conductive, both hysteresis losses and the generation of eddy currents will contribute to the heating of the susceptor.
  • the susceptor is magnetic, but not conductive, then hysteresis losses will be the only means by which the susceptor will heat, when penetrated by an alternating magnetic field.
  • the susceptor may be electrically conductive or magnetic or both electrically conductive and magnetic.
  • An alternating magnetic field generated by one or several induction coils heat the susceptor, which then transfers the heat to the aerosol-forming substrate, such that an aerosol is formed.
  • the heat transfer may be mainly by conduction of heat. Such a transfer of heat is best, if the susceptor is in close thermal contact with the aerosol-forming substrate.
  • an aerosol-generating article refers to an article comprising an aerosol-forming substrate that is capable of releasing volatile compounds that can form an aerosol.
  • an aerosol-generating article may be a smoking article that generates an aerosol that is directly inhalable into a user’s lungs through the user's mouth.
  • An aerosolgenerating article may be disposable.
  • aerosol-forming substrate relates to a substrate capable of releasing one or more volatile compounds that can form an aerosol. Such volatile compounds may be released by heating the aerosol-forming substrate.
  • An aerosol-forming substrate may conveniently be part of an aerosol-generating article or smoking article.
  • the aerosol-forming substrate may be a solid aerosol-forming substrate.
  • the aerosolforming substrate may comprise both solid and liquid components.
  • the aerosol-forming substrate may comprise a tobacco-containing material containing volatile tobacco flavour compounds which are released from the substrate upon heating.
  • the aerosol-forming substrate may comprise a non-tobacco material.
  • the aerosol-forming substrate may comprise an aerosol former that facilitates the formation of a dense and stable aerosol. Examples of suitable aerosol formers are glycerine and propylene glycol.
  • the aerosol-generating substrate preferably comprises homogenised tobacco material, an aerosol-former and water.
  • the aerosol-generating substrate most preferably comprises cut filler and glycerin as an aerosol former.
  • Providing homogenised tobacco material may improve aerosol generation, the nicotine content and the flavour profile of the aerosol generated during heating of the aerosol-generating article.
  • the process of making homogenised tobacco involves grinding tobacco leaf, which more effectively enables the release of nicotine and flavours upon heating.
  • the term “longitudinal” is used to describe the direction between the upstream end and the downstream end of the aerosolgenerating article. During use, air is drawn through the aerosol-generating article in the longitudinal direction.
  • the term “length” is used to describe the maximum dimension of the aerosol-generating article or a component of the aerosolgenerating article in the longitudinal direction.
  • transverse is used to describe the direction perpendicular to the longitudinal direction. Unless otherwise stated, references to the “cross-section” of the aerosol-generating article or a component of the aerosolgenerating article refer to the transverse cross-section.
  • the term “width” denotes the maximum dimension of the aerosol-generating article or a component of the aerosol-generating article in a transverse direction. Where the aerosol-generating article has a substantially circular cross-section, the width of the aerosol-generating article corresponds to the diameter of the aerosol-generating article. Where a component of the aerosol-generating article has a substantially circular cross-section, the width of the component of the aerosol-generating article corresponds to the diameter of the component of the aerosol-generating article.
  • the resistance to draw (RTD) of the aerosol-generating article or a component of the aerosol-generating article is measured in accordance with ISO 6565-2015 at a volumetric flow rate of about 17.5 millilitres per second at the proximal end or downstream end of the aerosol-generating article or the component thereof at a temperature of about 22 degrees Celsius, a pressure of about 101 kPa (about 760 Torr) and a relative humidity of about 60%.
  • Example Ex.1 An upstream element for an aerosol-generating article, wherein the upstream element is formed of a non-woven material.
  • Example Ex2 The upstream element of example EX1 , wherein the upstream element is formed of an airlaid non-woven material.
  • Example Ex3 The upstream element of example Ex1 , wherein the non-woven material is a wetlaid non-woven material.
  • Example Ex4 The upstream element according to example Ex2 or Ex3, wherein the airlaid non-woven material or the wetlaid non-woven material comprises a biodegradable material.
  • Example Ex5 The upstream element according to any one of examples Ex2, Ex3 or Ex4 wherein the airlaid non-woven material or the wetlaid non-woven material comprises cellulose fibres.
  • Example Ex6 The upstream element according to any one of examples Ex2to Ex5, wherein the airlaid non-woven material or the wetlaid non-woven material comprises at least 90 percent by weight cellulose.
  • Example Ex7 The upstream element according to any of examples Ex2 to Ex6, wherein the airlaid non-woven material or the wetlaid non-woven material comprises at least 95 percent by weight cellulose.
  • Example Ex8 The upstream element according to any of examples Ex2 to Ex7, wherein the airlaid non-woven material or the wetlaid non-woven material comprises at least 99 percent by weight cellulose.
  • Example Ex9 The upstream element according to any of examples Ex2 to Ex8, wherein the airlaid non-woven material or the wetlaid non-woven material comprises 100 percent by weight cellulose.
  • Example Ex10 The upstream element according to any of examples Ex2 to Ex9, wherein the airlaid non-woven material or the wetlaid non-woven material comprises a fibre web material.
  • Example Ex11 The upstream element according to example Ex10, wherein the airlaid non-woven material or the wetlaid non-woven material comprises bonded webs.
  • Example Ex12 The upstream element according to example Ex11 , wherein the bonded webs are high pressure bonded webs.
  • Example Ex13 The upstream element according to example Ex11 or Ex12, wherein the bonded webs are hydroentangled bonded webs.
  • Example Ex14 The upstream element according to any of examples Ex2 to Ex13 , wherein the airlaid non-woven material or the wetlaid non-woven material has a weight per surface area of at least 15 grams per metre squared.
  • Example Ex15 The upstream element according to any of examples Ex2 to Ex14, wherein the airlaid non-woven material or the wetlaid non-woven material has a weight per surface area of at least 30 grams per metre squared.
  • Example Ex16 The upstream element according to any of examples Ex2 to Ex15, wherein the airlaid non-woven material or the wetlaid non-woven material has a weight per surface area of at least 50 grams per metre squared.
  • Example Ex17 The upstream element according to any of examples Ex2 to Ex16, wherein the airlaid non-woven material or the wetlaid non-woven material has a weight per surface area of at least 60 grams per metre squared.
  • Example Ex18 The upstream element according to any of examples Ex2 to Ex17, wherein the airlaid non-woven material or the wetlaid non-woven material has a weight per surface area of up to 600 grams per metre squared.
  • Example Ex19 The upstream element according to any of examples Ex2 to Ex18, wherein the airlaid non-woven material or the wetlaid non-woven material has a weight per surface area of up to 200 grams per metre squared.
  • Example Ex20 The upstream element according to any of examples Ex2 to Ex19, wherein the airlaid non-woven material or the wetlaid non-woven material has a weight per surface area of up to 70 grams per metre squared.
  • Example Ex21 The upstream element according to any of examples Ex2 to Ex13, wherein the airlaid non-woven material or the wetlaid non-woven material has a weight per surface areas between 15 grams per metre squared and 600 grams per metre squared.
  • Example Ex22 The upstream element according to any of examples Ex2 to Ex13, wherein the airlaid non-woven material or the wetlaid non-woven material has a weight per surface area of between 30 grams per metre squared and 200 grams per metre squared.
  • Example Ex23 The upstream element according to any of examples Ex2 to Ex13, wherein the airlaid non-woven material or the wetlaid non-woven material has a weight per surface area of between 60 grams per metre squared and 180 grams per metre squared.
  • Example Ex24 The upstream element according to any of examples Ex2 to Ex13, wherein the airlaid non-woven material or the wetlaid non-woven material has a weight per surface area of 62 grams per metre squared.
  • Example Ex25 The upstream element according to any of examples Ex2 to Ex13, wherein the airlaid non-woven material or the wetlaid non-woven material has a weight per surface area of 170 grams per metre squared.
  • Example Ex26 The upstream element according to any of examples Ex2 to Ex25, wherein the airlaid non-woven material or the wetlaid non-woven material is a sheet.
  • Example Ex27 The upstream element according to example Ex26, wherein the sheet has a bobbin width of at least 400 millimetres.
  • Example Ex28 The upstream element according to example Ex26 or Ex27, wherein the sheet has a bobbin width of up to 500 millimetres.
  • Example Ex29 The upstream element according to example Ex26, wherein the sheet has a bobbin width of between 400 millimetres and 500 millimetres.
  • Example Ex30 The upstream element according to example Ex26, wherein the sheet has a bobbin width of at least 120 millimetres.
  • Example Ex31 The upstream element according to example Ex26 or Ex30, wherein the sheet has a bobbin width of up to 210 millimetres.
  • Example Ex32 The upstream element according to example Ex26, wherein the sheet has a bobbin width of between 120 millimetres and 210 millimetres.
  • Example Ex33 The upstream element according to any of examples Ex2 to Ex32, wherein the airlaid non-woven material or the wetlaid non-woven material is a crimped non-woven material.
  • Example Ex34 The upstream element according to any of examples Ex2 to Ex33, wherein the upstream element comprises a particle retention feature.
  • Example Ex35 The upstream element according to any of examples Ex2 to Ex34, wherein the crimped non-woven material includes a longitudinal fold.
  • Example Ex36 The upstream element according to example Ex35, wherein the crimped non-woven material includes a plurality of longitudinal folds.
  • Example Ex37 The upstream element according to example Ex36, wherein each longitudinal fold is spaced from its adjacent longitudinal fold or folds by a distance.
  • Example Ex38 The upstream element according to example Ex37, wherein the distance between adjacent longitudinal folds is less than 1000 micrometres.
  • Example Ex39 The upstream element according to example Ex37 or Ex38, wherein the distance between adjacent longitudinal folds is less than 750 micrometres.
  • Example Ex40 The upstream element according to example Ex37, Ex38 or Ex39, wherein the distance between adjacent longitudinal folds is less than 500 micrometres.
  • Example Ex41 The upstream element according to any of examples Ex37 to Ex40, wherein the distance between adjacent longitudinal folds is at least 25 micrometres.
  • Example Ex42 The upstream element according to any of examples Ex37 to Ex41 , wherein the distance between adjacent longitudinal folds is at least 50 micrometres.
  • Example Ex44 The upstream element according to example Ex37, wherein the distance between adjacent longitudinal folds is between 25 micrometres and 1000 micrometres.
  • Example Ex45 The upstream element according to example Ex44, wherein the distance between adjacent longitudinal folds is between 25 micrometres and 750 micrometres.
  • Example Ex46 The upstream element according to example Ex44 or Ex45, wherein the distance between adjacent longitudinal folds is between 25 micrometres and 500 micrometres.
  • Example Ex47 The upstream element according to example Ex37, wherein the distance between adjacent longitudinal folds is between 50 micrometres and 1000 micrometres.
  • Example Ex48 The upstream element according to example Ex47, wherein the distance between adjacent longitudinal folds is between 50 micrometres and 750 micrometres.
  • Example Ex49 The upstream element according to example Ex47 or Ex48, wherein the distance between adjacent longitudinal folds is between 50 micrometres and 500 micrometres.
  • Example Ex50 The upstream element according to example Ex37, wherein the distance between adjacent longitudinal folds is between 100 micrometres and 1000 micrometres.
  • Example Ex51 The upstream element according to example Ex50, wherein the distance between adjacent longitudinal folds is between 100 micrometres and 750 micrometres.
  • Example Ex52 The upstream element according to example Ex50 or Ex51 , wherein the distance between adjacent longitudinal folds is between 100 micrometres and 500 micrometres.
  • Example Ex53 The upstream element according to any of examples Ex37 to Ex52, wherein the or each longitudinal fold has a height and wherein the height of the or each longitudinal fold corresponds to the distance between adjacent longitudinal folds.
  • Example Ex54 The upstream element according to example Ex53, wherein the height of the or each longitudinal fold is less than 1000 micrometres.
  • Example Ex55 The upstream element according to example Ex53 or Ex54, wherein the height of the or each longitudinal fold is less than 750 micrometres.
  • Example Ex56 The upstream element according to example Ex53, Ex54 or Ex55, wherein the height of the or each longitudinal fold is less than 500 micrometres.
  • Example Ex57 The upstream element according to any of examples Ex53 to Ex56, wherein the height of the or each longitudinal fold is at least 25 micrometres.
  • Example Ex58 The upstream element according to any of examples Ex53 to Ex57, wherein the height of the or each longitudinal fold is at least 50 micrometres.
  • Example Ex59 The upstream element according to any of examples Ex53 to Ex58, wherein the height of the or each longitudinal fold is at least 100 micrometres.
  • Example Ex60 The upstream element according to example Ex53, wherein the height of the or each longitudinal fold is between 25 micrometres and 1000 micrometres.
  • Example Ex61 The upstream element according to example Ex60, wherein the height of the or each longitudinal fold is between 25 micrometres and 750 micrometres.
  • Example Ex62 The upstream element according to example Ex60 or Ex61 , wherein the height of the or each longitudinal fold is between 25 micrometres and 500 micrometres.
  • Example Ex63 The upstream element according to example Ex53, wherein the height of the or each longitudinal fold is between 50 micrometres and 1000 micrometres.
  • Example Ex64 The upstream element according to example Ex63, wherein the height of the or each longitudinal fold is between 50 micrometres and 750 micrometres.
  • Example Ex65 The upstream element according to example Ex63 or Ex64, wherein the height of the or each adjacent longitudinal fold is between 50 micrometres and 500 micrometres.
  • Example Ex66 The upstream element according to example Ex53, wherein the height of the or each longitudinal fold is between 100 micrometres and 1000 micrometres.
  • Example Ex69 The upstream element according to any of examples Ex2 to Ex68, wherein the upstream element has a length of 5 millimetres.
  • Example Ex72 The upstream element according to any of examples Ex2 to Ex71 , wherein the airlaid non-woven material or the wetlaid non-woven material has a bulk density inside the upstream element of about 0.13 milligrams per cubic millimetre.
  • Example Ex75 An upstream element for an aerosol-generating article, wherein the upstream element comprises a non-woven material, wherein the non-woven material is formed by an airlaying or an airforming process or a wetlaying or a wetforming process.
  • Example Ex78 The upstream element according to example Ex75, Ex76 or Ex77, wherein the airlaid non-woven material or the wetlaid non-woven material is pulled between a first roller having at least one outer ridge and a second roller having at least one outer groove, wherein the at least one outer ridge and the at least one outer groove are complementary, such that a corrugation pattern is formed on the airlaid non-woven material.
  • Example Ex79 The upstream element according to example Ex78, wherein the airlaid non-woven material or the wetlaid non-woven material is pulled between the first roller and the second roller in a direction and wherein the corrugation pattern is aligned with the direction in which the airlaid non-woven material or the wetlaid non-woven material is pulled.
  • Example Ex80 The upstream element according to example Ex78 or Ex79, wherein the corrugation pattern is a longitudinal corrugation pattern.
  • Example Ex81 The upstream element according to claim Ex78, Ex79 or Ex80, wherein the corrugation pattern includes a plurality of longitudinal folds.
  • Example Ex83 The upstream element according to example Ex82, wherein the distance between adjacent longitudinal folds is less than 1000 micrometres.
  • Example Ex84 The upstream element according to example Ex82 or Ex83, wherein the distance between adjacent longitudinal folds is less than 750 micrometres.
  • Example Ex85 The upstream element according to example Ex82, Ex83 or Ex84, wherein the distance between adjacent longitudinal folds is less than 500 micrometres.
  • Example Ex86 The upstream element according to any of examples Ex82 to Ex85, wherein the distance between adjacent longitudinal folds is at least 25 micrometres.
  • Example Ex89 The upstream element according to example Ex82, wherein the distance between adjacent longitudinal folds is between 25 micrometres and 1000 micrometres.
  • Example Ex90 The upstream element according to example Ex89, wherein the distance between adjacent longitudinal folds is between 25 micrometres and 750 micrometres.
  • Example Ex92 The upstream element according to example Ex82, wherein the distance between adjacent longitudinal folds is between 50 micrometres and 1000 micrometres.
  • Example Ex93 The upstream element according to example Ex92, wherein the distance between adjacent longitudinal folds is between 50 micrometres and 750 micrometres.
  • Example Ex94 The upstream element according to example Ex92 or Ex93, wherein the distance between adjacent longitudinal folds is between 50 micrometres and 500 micrometres.
  • Example Ex95 The upstream element according to example Ex82, wherein the distance between adjacent longitudinal folds is between 100 micrometres and 1000 micrometres.
  • Example Ex96 The upstream element according to example Ex95, wherein the distance between adjacent longitudinal folds is between 100 micrometres and 750 micrometres.
  • Example Ex97 The upstream element according to example Ex95 or Ex96, wherein the distance between adjacent longitudinal folds is between 100 micrometres and 500 micrometres.
  • Example Ex98 The upstream element according to example Ex82, wherein the or each longitudinal fold has a height and wherein the height of the or each longitudinal fold corresponds to the distance between adjacent longitudinal folds.
  • Example Ex99 The upstream element according to example Ex98, wherein the height of the or each longitudinal fold is less than 1000 micrometres.
  • Example Ex100 The upstream element according to example Ex98 or Ex99, wherein the height of the or each longitudinal fold is less than 750 micrometres.
  • Example Ex101 The upstream element according to example Ex98, Ex99 or Ex100, wherein the height of the or each longitudinal fold is less than 500 micrometres.
  • Example Ex102 The upstream element according to any of examples Ex98 to Ex101 , wherein the height of the or each longitudinal fold is at least 25 micrometres.
  • Example Ex103 The upstream element according to any of examples Ex98 to Ex102, wherein the height of the or each longitudinal fold is at least 50 micrometres.
  • Example Ex104 The upstream element according to any of examples Ex98 to Ex103, wherein the height of the or each longitudinal fold is at least 100 micrometres.
  • Example Ex105 The upstream element according to example Ex98, wherein the height of the or each longitudinal fold is between 25 micrometres and 1000 micrometres.
  • Example Ex106 The upstream element according to example Ex105, wherein the height of the or each longitudinal fold is between 25 micrometres and 750 micrometres.
  • Example Ex107 The upstream element according to example Ex105 or Ex106, wherein the height of the or each longitudinal fold is between 25 micrometres and 500 micrometres.
  • Example Ex108 The upstream element according to example Ex98, wherein the height of the or each longitudinal fold is between 50 micrometres and 1000 micrometres.
  • Example Ex109 The upstream element according to example Ex108, wherein the height of the or each longitudinal fold is between 50 micrometres and 750 micrometres.
  • Example Ex110 The upstream element according to example Ex108 or Ex109, wherein the height of the or each adjacent longitudinal fold is between 50 micrometres and 500 micrometres.
  • Example Ex111 The upstream element according to example Ex98, wherein the height of the or each longitudinal fold is between 100 micrometres and 1000 micrometres.
  • Example Ex112 The upstream element according to example Ex111 , wherein the height of the or each longitudinal fold is between 100 micrometres and 750 micrometres.
  • Example Ex113 The upstream element according to example Ex111 or Ex112, wherein the height of the or each longitudinal fold is between 100 micrometres and 500 micrometres.
  • Example Ex114 The upstream element according to any of examples Ex75 to Ex113, wherein the airlaid non-woven material is subjected to one or more further processes in order to control the distance between adjacent longitudinal folds.
  • Example Ex115 The upstream element according to example Ex114, wherein the one or more further processes includes an embossing process.
  • Example Ex116 The upstream element according to example Ex114 or Ex115, wherein the corrugated airlaid non-woven material or the corrugated wetlaid non-woven material is pulled through a funnel device in order to form a cylinder.
  • Example Ex117 The upstream element according to example Ex116, wherein the cylinder is wrapped.
  • Example Ex118 The upstream element according to example Ex116 or Ex117, wherein the cylinder is cut into one or more plugs.
  • Example Ex119 The upstream element according to example Ex118, wherein the upstream element is a plug.
  • Example Ex120 The upstream element according to example Ex118 or Ex119, wherein the upstream element is a front plug.
  • Example Ex121 A method of manufacturing an upstream element, the method comprising airlaying a sheet of non-woven material, forming a cylinder of the airlaid non-woven material, wrapping the cylinder and cutting the cylinder into one or more plugs.
  • Example Ex122 The method according to example Ex121 , the method further comprising crimping the airlaid non-woven material.
  • Example Ex123 The method according to example Ex121 or Ex122, the method further comprising embossing the airlaid non-woven material.
  • Example Ex124 A method of manufacturing an upstream element, the method comprising wetlaying a sheet of non-woven material, forming a cylinder of the wetlaid non-woven material, wrapping the cylinder and cutting the cylinder into one or more plugs.
  • Example Ex125 The method according to example Ex124, the method further comprising crimping the wetlaid non-woven material.
  • Example Ex126 The method according to example Ex124 or Ex125, the method further comprising embossing the wetlaid non-woven material.
  • Example Ex127 An aerosol-generating article comprising an aerosol-generating substrate and an upstream element according to any of examples EX1 to Ex120, wherein the upstream element is located upstream of the aerosol-generating substrate.
  • Example Ex128 The aerosol-generating article according to example Ex127, wherein the upstream element is the most upstream plug of the aerosol-generating article.
  • Example Ex129 The aerosol-generating article according to example Ex127 or Ex128 comprising a downstream element.
  • Example Ex130 The aerosol-generating article according to example Ex129, wherein the downstream element comprises one or more ventilation holes.
  • Example Ex131 The aerosol-generating article according to example Ex130 wherein the one or more ventilation holes are arranged around a periphery of the downstream element.
  • Example Ex132 The aerosol-generating article according to example Ex130 or Ex131 , wherein the one or more ventilation holes are arranged around a circumference of the downstream element.
  • Example Ex133 The aerosol-generating article according to any of examples Ex127 to Ex132 comprising a mouthpiece filter.
  • Example Ex134 An aerosol-generating device comprising an aerosol-generating article according to any of examples Ex127 to Ex133, wherein the aerosol-generating device is configured to heat the aerosol-generating substrate of the aerosol-generating article.
  • Example Ex135 The aerosol-generating device according to example Ex134, wherein the aerosol-generating device comprises a housing defining a cavity configured to receive the aerosol-generating article. Examples will now be further described with reference to the figures in which:
  • Figure 1 is a schematic illustration of an aerosol-generating article including an upstream element according to the invention
  • Figure 2 is a flow chart showing steps in an airlaying process
  • Figure 3 is a schematic illustration of crimping rollers
  • Figure 4 is a flow chart showing steps in a crimping process.
  • the aerosol-generating article 10 has a cylindrical body, which has a downstream or proximal end 12 and an upstream or distal end 14.
  • the aerosol-generating article 10 is configured to be inserted into a tubular cavity of an electronic aerosol-generating device (not shown) in which it is electrically heated.
  • the downstream end 12 is intended to stay outside of the aerosol-generating device and includes a mouthpiece filter 16, which is to be put between the lips of a user and may include a filter.
  • the upstream end 14 is intended to be put inside the aerosol-generating device and includes a substrate portion 18, which comprises an aerosol-generating substrate including aerosol-generating material, such as a tobacco-containing material, and an upstream element, in the form of a front plug 20.
  • the front plug 20 protects the aerosol-generating substrate within the substrate portion 18 from outside conditions.
  • the aerosol-generating article 10 may include other plugs 22, e.g. plugs which provide a cooling function, intermediate the downstream end 12 and the upstream end 14.
  • the front plug 20 prevents by-products of the aerosol-generating article 10 from entering the aerosol-generating device.
  • by-products include liquid slurry, made from a combination of water (from air humidity) and the heated aerosol-generating material, and particles of the aerosol-generating material which may become dry and brittle after the heating cycle.
  • the front plug 20 of the invention is formed from a non-woven material that is produced by an airlaying process 100, as will be described with reference to Figure 2.
  • step 102 fibres of a material comprising at least 90 percent cellulose are mixed with air. This results in the formation of a uniform air-fibre mixture.
  • the uniform air-fibre mixture is deposited on a moving air- permeable belt or wire (step 104) to form a web.
  • step 106 the webs are bonded, for example with latex, using a high pressure bonding process such as hydroentanglement.
  • the material is compressed such that the pulp fibres are connected with each other in the ‘pressed’ areas.
  • FIG. 3 there is shown a sheet of airlaid non-woven material 30, a first crimping roller 32, a second crimping roller 34 and a crimped sheet of airlaid non-woven material 36.
  • the first and second crimping rollers 32, 34 have complementary ridges and grooves (not shown) on their outer surfaces.
  • a continuous band or sheet 30 of the airlaid non-woven material is pulled through the first crimping roller 32 and the second crimping roller 34 as the crimping rollers 32, 34 are rotated. This creates a corrugation pattern on the crimped sheet 36.
  • the crimping ridges are aligned with the direction of the moving band of material, i.e. the crimping ridges are longitudinal.
  • the corrugated material 36 is pulled through a funnel-shaped device in order to form a compressed rod.
  • the compressed rod is then wrapped and cut into plugs 20 which can be used in an aerosolgenerating article 10 (step 206).
  • the crimping process advantageously allows the structure and properties of the non-woven material to be adjusted to produce the desired profile for the front plug 20.
  • One or more additional processes may be employed to further optimize the properties of the front plug, for example to helping to ensure a desired distance between two adjacent folds is achieved.
  • An embossing process may, for example, be used to create a random pattern in relief, in which the heights of the folds are the same as the distance between two adjacent folds.
  • the random relief pattern advantageously prevents two adjacent folds in the non-woven material having patterns that match each other and then getting stuck to each other.
  • the desired distance between two adjacent folds is related to the Particle Size Distribution of aerosol-generating substrate used for the aerosol-generating article.
  • the distance to target between adjacent folds of the plug 20 could be evaluated according to the desired particle size distribution, the acceptable particles loss, the desired resistance to draw of the crimped front plug 20 and the length of the crimped front plug 20.
  • the folds may thus be considered to be particle retention features.
  • the front plug 20 of the invention is formed from a non-woven material that is produced by an airlaying process 100, it will be appreciated that in other examples of the invention, the front plug 20 of the invention may be formed from a nonwoven material that may be produced, for example, by a wetlaying process.
  • the resistance to draw of the front plug 20 is related to the desired distance between adjacent folds and to the length of the front plug 20. The shorter the distance or the longer the plug, the higher the resistance to draw.
  • the resistance to draw is directly related to the width of the sheet to be crimped. The wider the sheet, the more material will be compressed to fit inside the front plug cavity, the higher the resistance to draw.
  • the front plug 20 of the present invention has been found to have a similar resistance to draw to conventional front plugs, which comprise plastic materials.
  • the front plug 20 of the present invention is more temperature resistant than conventional, plastic-containing, front plugs. This improves the aesthetics of the product, as well as its resistance to draw. It has also been found that the front plug 20 of the present invention scrapes the inner walls of the heating cavity of aerosol-generating devices, thereby cleaning dirt and elements which may have accidentally entered the heating cavity.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Biodiversity & Conservation Biology (AREA)
  • Disinfection, Sterilisation Or Deodorisation Of Air (AREA)

Abstract

L'invention concerne un élément amont (20) pour un article de génération d'aérosol (10). L'élément amont (20) est formé d'un matériau non tissé. L'élément amont (20) comprend une caractéristique de rétention de particules qui comprend une pluralité de plis longitudinaux. Chaque pli longitudinal est espacé de son pli longitudinal adjacent ou de plis longitudinaux selon une distance comprise entre 25 micromètres et 1000 micromètres. Chaque pli longitudinal a une hauteur qui correspond à la distance entre des plis longitudinaux adjacents et est comprise entre 25 micromètres et 1000 micromètres.
PCT/EP2024/068405 2023-07-07 2024-06-28 Élément amont amélioré Pending WO2025011989A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP23386057.6 2023-07-07
EP23386057 2023-07-07

Publications (1)

Publication Number Publication Date
WO2025011989A1 true WO2025011989A1 (fr) 2025-01-16

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Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2013098410A2 (fr) 2011-12-30 2013-07-04 Philip Morris Products S.A. Article à fumer comprenant un bouchon avant et procédé
WO2015176898A1 (fr) 2014-05-21 2015-11-26 Philip Morris Products S.A. Article produisant un aérosol avec suscepteur interne
WO2020115151A1 (fr) 2018-12-06 2020-06-11 Philip Morris Products S.A. Article de génération d'aérosol avec un contenu de générateur d'aérosol élevé
EP3612043B1 (fr) * 2017-04-19 2021-02-17 Philip Morris Products S.a.s. Procédé de production de matière de tabac en forme de feuille
US20220000177A1 (en) * 2017-06-22 2022-01-06 Japan Tobacco Inc. Flavor generating segment, and flavor generating article and flavor inhalation system equipped therewith
WO2023126504A2 (fr) * 2021-12-29 2023-07-06 Nicoventures Trading Limited Composant pour un système de distribution et procédé et appareil de fabrication d'un composant pour un système de distribution
WO2024153942A1 (fr) * 2023-01-19 2024-07-25 Nicoventures Trading Limited Procédés et ensembles pour la fabrication d'un composant creux destiné à être utilisé dans ou avec un système de fourniture d'aérosol
WO2024153943A2 (fr) * 2023-01-19 2024-07-25 Nicoventures Trading Limited Procédés et ensembles pour le traitement d'une feuille continue d'un matériau

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2013098410A2 (fr) 2011-12-30 2013-07-04 Philip Morris Products S.A. Article à fumer comprenant un bouchon avant et procédé
WO2015176898A1 (fr) 2014-05-21 2015-11-26 Philip Morris Products S.A. Article produisant un aérosol avec suscepteur interne
EP3612043B1 (fr) * 2017-04-19 2021-02-17 Philip Morris Products S.a.s. Procédé de production de matière de tabac en forme de feuille
US20220000177A1 (en) * 2017-06-22 2022-01-06 Japan Tobacco Inc. Flavor generating segment, and flavor generating article and flavor inhalation system equipped therewith
WO2020115151A1 (fr) 2018-12-06 2020-06-11 Philip Morris Products S.A. Article de génération d'aérosol avec un contenu de générateur d'aérosol élevé
WO2023126504A2 (fr) * 2021-12-29 2023-07-06 Nicoventures Trading Limited Composant pour un système de distribution et procédé et appareil de fabrication d'un composant pour un système de distribution
WO2024153942A1 (fr) * 2023-01-19 2024-07-25 Nicoventures Trading Limited Procédés et ensembles pour la fabrication d'un composant creux destiné à être utilisé dans ou avec un système de fourniture d'aérosol
WO2024153943A2 (fr) * 2023-01-19 2024-07-25 Nicoventures Trading Limited Procédés et ensembles pour le traitement d'une feuille continue d'un matériau

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