CN113811204A

CN113811204A - Aerosol-generating article comprising an aerosol-cooling element having elongate protrusions

Info

Publication number: CN113811204A
Application number: CN202080035147.8A
Authority: CN
Inventors: R·N·巴蒂斯塔; E·圭多蒂
Original assignee: Philip Morris Products SA
Current assignee: Philip Morris Products SA
Priority date: 2019-06-05
Filing date: 2020-05-27
Publication date: 2021-12-17
Also published as: WO2020245010A1; EP3979850A1; KR20220016813A; BR112021022147A2; JP2022535394A; US20220232885A1

Abstract

The present invention provides an aerosol-generating article (10) for generating an aerosol when heated. An aerosol-generating article (10) comprises a rod (12) of aerosol-generating substrate and an aerosol-cooling element (16) positioned downstream of the rod (12) of aerosol-generating substrate. The aerosol-cooling element (16) comprises a hollow tubular section (8) comprising a peripheral wall (24). The hollow tubular section (8) extends along a longitudinal axis and has an upstream end and a downstream end in fluid communication. The hollow tubular section (8) comprises at least one elongate protrusion (26) extending from the peripheral wall (24) into the interior of the hollow tubular section (8). At least one elongated projection (26) extends longitudinally from an upstream location on the peripheral wall (24) to a downstream location on the peripheral wall (24) downstream of the upstream location. The aerosol-generating article (10) further comprises a wrapper (18) defining a rod (12) of aerosol-generating substrate and 15 a first aerosol-cooling element (16).

Description

Aerosol-generating article comprising an aerosol-cooling element having elongate protrusions

Technical Field

The present disclosure relates to an aerosol-cooling element for use in an aerosol-generating article comprising an aerosol-generating substrate and adapted to generate an inhalable aerosol upon heating, and an aerosol-generating article comprising such an aerosol-cooling element.

Background

Aerosol-generating articles in which an aerosol-generating substrate (such as a tobacco-containing substrate) is heated rather than combusted are known in the art. Typically, in such heated smoking articles, an aerosol is generated by transferring heat from a heat source to a physically separate aerosol-generating substrate or material, which may be positioned in contact with the heat source, either internally, 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 entrained in air drawn through the aerosol-generating article. As the released compound cools, the compound condenses to form an aerosol.

A number of prior art documents disclose aerosol-generating devices for consuming aerosol-generating articles. Such devices include, for example, electrically heated aerosol-generating devices in which an aerosol is generated by transferring heat from one or more electric heater elements of the aerosol-generating device to an aerosol-generating substrate of a heated aerosol-generating article.

In the past, randomly oriented fragments, strands or sticks of tobacco material have typically been used to produce substrates for heated aerosol-generating articles. More recently, alternative substrates for aerosol-generating articles to be heated rather than combusted, such as rods formed from gathered sheets of tobacco material, have been disclosed. For example, the strips disclosed in international patent application WO-A-2012/164009 have A longitudinal porosity which allows air to be drawn through the strip. As A further alternative, international patent application WO-A-2011/101164 discloses rods for heated aerosol-generating articles formed from A rod of homogenized tobacco material, which rods may be formed by casting, rolling, calendering or extruding A mixture comprising particulate tobacco and at least one aerosol former to form sheets of homogenized tobacco material. In another embodiment, the rod of WO-A-2011/101164 may be formed from A rod of homogenized tobacco material obtained by extruding A mixture comprising particulate tobacco and at least one aerosol former to form A continuous length of homogenized tobacco material.

The substrate for a heated aerosol-generating article typically also comprises an aerosol former, i.e. a compound or mixture of compounds which in use facilitates formation of an aerosol and is preferably substantially resistant to thermal degradation at the operating temperature of the aerosol-generating article. Examples of suitable aerosol-forming agents include, but are not limited to: polyhydric alcohols such as propylene glycol, triethylene glycol, 1, 3-butylene glycol, glycerin; esters of polyhydric alcohols such as monoacetin, diacetin, or triacetin; and fatty acid esters of monocarboxylic, dicarboxylic or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate.

It is also common to include one or more add-on elements in an aerosol-generating article for generating an inhalable aerosol upon heating, the one or more add-on elements being assembled in the same package as the substrate. Examples of such additional elements include mouthpiece filter segments, support elements adapted to impart structural strength to the aerosol-generating article.

It is also proposed to include a cooling element in the aerosol-generating article for generating an inhalable aerosol when heated, the cooling element being adapted to cool the aerosol before it reaches the mouthpiece. For example, WO 2013/120565 discloses an aerosol-generating article comprising an aerosol-forming substrate and an aerosol-cooling element located downstream of the aerosol-forming substrate within the rod. In an embodiment, the aerosol-generating element comprises a crimped sheet of polylactic acid (PLA) gathered to define a plurality of longitudinally extending channels. When an aerosol stream is drawn through the aerosol-cooling element, heat can be transferred from the aerosol to the sheet of PLA.

When using aerosol-generating articles of the above-described type under particularly hot and humid weather conditions, such as those often encountered in countries characterised by tropical climates, the mouthpiece of the article may reach temperatures as high as 42 to 45 degrees celsius. These temperatures may be associated with a feeling of discomfort or slight pain to some consumers, as sensitive tissues such as lips, mouth, tongue and mucous membranes may often come into direct contact with the surface of the mouthpiece during use. Without wishing to be bound by theory, this is understood because thermo-receptors that respond to an increase in skin temperature respond most quickly at about 45 degrees celsius. In contrast, the warming receptors are spontaneously active when the temperature of the skin is around 30 to 36 degrees celsius, but there is generally no awareness of warmth (neutral hot zone). In addition, the skin contains heat sensitive receptors, called thermal nociceptors, which cause pain when the skin temperature rises above 45 degrees celsius. This is because nociceptors that respond to temperature are intended to signal the central nervous system: tissue damage may be imminent and the affected body part should be immediately withdrawn from the heat source.

It is therefore desirable to provide a new and improved aerosol-cooling element for an aerosol-generating article, which is adapted to optimize the cooling of an aerosol delivered to a consumer. It is also desirable to provide a new and improved aerosol-cooling element for an aerosol-generating article which is adapted to optimise the cooling of the surface of the mouth end of the article which may come into contact with sensitive tissues of a consumer during use. At the same time, it is desirable to provide such aerosol-generating articles that can be manufactured efficiently and at high speeds without requiring major modifications to existing equipment and devices.

Disclosure of Invention

The present invention relates to an aerosol-cooling element configured for use in an aerosol-generating article. The aerosol-cooling element may comprise a hollow tubular section comprising a peripheral wall. The hollow tubular section may extend along a longitudinal axis and may have upstream and downstream ends in fluid communication. The hollow tubular section may comprise at least one elongate protrusion extending from the peripheral wall into the interior of the hollow tubular section. At least one elongated projection extends longitudinally from an upstream location on the peripheral wall to a downstream location on the peripheral wall downstream of the upstream location.

According to a first aspect of the present disclosure, there is provided an aerosol-generating element configured for use in an aerosol-generating article. The aerosol-cooling element comprises a hollow tubular section comprising a circumferential wall. The hollow tubular section extends along a longitudinal axis and has an upstream end and a downstream end in fluid communication. The hollow tubular section includes at least one elongated protrusion extending from the peripheral wall into the interior of the hollow tubular section. The at least one elongated projection may extend longitudinally from an upstream location on the perimeter wall to a downstream location on the perimeter wall downstream of the upstream location.

The term "aerosol-generating article" is used herein with reference to the present invention to describe an article in which an aerosol-generating substrate is heated to produce an aerosol and deliver the aerosol to a consumer. The substrate as used is capable of releasing volatile compounds upon heating to generate an aerosol.

Conventional cigarettes are lit when a smoker 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 be lit and the resulting combustion produces breathable smoke. In contrast, in heated aerosol-generating articles, an aerosol is generated by heating a flavour-generating substrate, such as tobacco. Known heated aerosol-generating articles include, for example, electrically heated aerosol-generating articles, as well as aerosol-generating articles in which an aerosol is generated by heat transfer from a combustible fuel element or heat source to a physically separate aerosol-forming material. For example, aerosol-generating articles according to the present invention find particular application in aerosol-generating systems comprising an electrically heated aerosol-generating device having an internal heater blade adapted for insertion into a rod of aerosol-generating substrate. Aerosol-generating articles of this type are described in the prior art (for example in european patent application EP 0822670).

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

During use, volatile compounds are released from the aerosol-generating substrate by heat transfer and become entrained in the air drawn through the aerosol-generating article. As the released compound cools, the compound condenses to form an aerosol that is inhaled by the consumer.

As used herein, the term "tubular element" means an elongated element that defines a lumen or airflow channel along its longitudinal axis. In the context of the present specification, the term "tubular" is intended to cover any tubular element having a substantially cylindrical cross-section, defining at least one gas flow conduit establishing fluid communication between an upstream end of the tubular element and a downstream end of the tubular element. As used herein with reference to the present invention, the term "hollow" is used to describe a tubular element defining an internal empty space (such as a chamber or cavity).

As used herein, the term "longitudinal" refers to a direction corresponding to the major longitudinal axis of an aerosol-generating article, which direction extends between an upstream end and a downstream end of the aerosol-generating article. As used herein, the terms "upstream" and "downstream" describe the relative position of an element or portion of an element of an aerosol-generating article with respect to the direction in which an aerosol is conveyed through the aerosol-generating article during use. During use, air is drawn through the aerosol-generating article in the longitudinal direction. The term "transverse" refers to a direction perpendicular to the longitudinal axis. Any reference to a "cross-section" of an aerosol-generating article or a component of an aerosol-generating article refers to a transverse cross-section, unless otherwise specified.

The term "length" denotes the largest dimension of a component of an aerosol-generating article in the longitudinal direction. For example, it may be used to indicate the dimension of the strip or tubular element in the longitudinal direction. In particular, in the context of the present invention, the term "length of the tubular element" is used to indicate the maximum distance between the upstream and downstream ends of the tubular element.

The term "peripheral wall" refers to a wall defining the periphery of the hollow tubular section. The term "perimeter" refers to an element or feature located at such a perimeter.

The term "elongated protrusion" refers to a protrusion or projection that is long relative to its width and thickness. For example, the elongated protrusion may comprise a flat surface. The height, circumferential and radial position of the elongated protrusion is taken with reference to the base of the elongated protrusion. The elongate projection is connected at its base to the inner surface of the peripheral wall of the hollow tubular section. The base of the elongated protrusion refers to the portion of the elongated protrusion that is connected to the inner surface of the peripheral wall of the hollow tubular section. The base of the elongated protrusion defines a longitudinal or axial position, a circumferential position, and a radial position of the elongated protrusion. For example, the radial position of the upstream position of the elongated projection refers to the radial position of the upstream position of the base of the elongated projection.

The term "radial position" refers to a direction along a radius from the center of an object, which in the present disclosure is a hollow tubular element, an aerosol-cooling element or an aerosol-generating article. In other words, a particular radial position of the elongated protrusion or a portion of the elongated protrusion refers to the position and distance of the elongated protrusion or a portion thereof with respect to the central axis of the hollow tubular section.

The term "circumferential position" refers to a direction along a circumference defined relative to the center (or central axis) of an object, which in the present disclosure is a hollow tubular element, an aerosol-cooling element or an aerosol-generating article. In other words, a particular circumferential position of the elongated protrusion or a portion of the elongated protrusion refers to the position and distance of the elongated protrusion or a portion thereof along a circumference defined relative to the central axis of the hollow tubular segment.

The term "thickness of the peripheral wall of the tubular element" is used in the present description to denote the minimum distance measured between the outer and inner surface of the wall of the tubular element. In practice, the distance at a given position is measured in a direction locally substantially perpendicular to the opposite sides of the wall of the tubular element. For a substantially cylindrical tubular element, i.e. a tubular element having a substantially circular cross-section, the thickness of the peripheral wall is evaluated as the distance between the outer surface and the inner surface of the peripheral wall measured in a substantially radial direction of the tubular element.

The expression "air-impermeable material" is used throughout the present specification to mean a material that does not allow fluids, in particular air and fumes, to pass through the voids or pores in the material. If the tubular support member is formed of a material that is impermeable to air and aerosol particles, the air and aerosol particles drawn through the support member are forced to flow through the airflow conduit, but are unable to flow through the wall of the support member.

In contrast, the term "porous" is used herein to refer to a material that provides a plurality of pores or openings that allow air to pass through the material.

As used in this specification, the term "homogenized tobacco material" encompasses any tobacco material formed by agglomeration of particles of tobacco material. A sheet or web of homogenized tobacco material is formed by agglomerating particulate tobacco obtained by grinding or otherwise powdering one or both of tobacco lamina and tobacco stem. In addition, the homogenized tobacco material may include small amounts of one or more of tobacco dust, tobacco fines, and other particulate tobacco by-products formed during processing, handling, and transport of the tobacco. The sheet of homogenized tobacco material may be produced by casting, extrusion, a papermaking process, or any other suitable process known in the art.

In the aerosol-generating article according to the invention, the aerosol-cooling element is adapted to reduce the temperature of the aerosol flowing through the article, while homogenizing the flow of the aerosol and finely controlling how the aerosol flow is delivered into the mouth of the consumer.

In more detail, it has been found that the structure and characteristics of the aerosol-cooling element are such as to consistently reduce the temperature of the gas stream in the article below a threshold value which may be associated with discomfort or pain to the consumer. Without wishing to be bound by theory, it will be appreciated that in aerosol-cooling elements and aerosol-generating articles according to the invention, as the material of the aerosol-cooling element heats up by conduction and convection, the heat of the aerosol flowing through the article is readily dissipated. At the same time, the at least one elongated protrusion extending into the interior of the aerosol-cooling element increases the inner surface area of the aerosol-cooling element. Increasing the inner surface area of the aerosol-cooling element means that there is more surface area between the aerosol flow and the material of the aerosol-cooling element for heat transfer. Thus, the temperature of the flowing aerosol is reduced and overheating of the outer surface of the article, which may come into contact with the lips of the consumer during use, is advantageously prevented, even if the article is used in particularly hot and humid weather conditions.

In addition to enhancing heat transfer from the aerosol-cooling element to the flowing aerosol, the at least one elongated projection partially blocks and diverts the heated aerosol entering and flowing through the aerosol-cooling element. The at least one elongated protrusion creates turbulence in the flowing aerosol which promotes mixing of the aerosol with cooler air already present in the aerosol-cooling element. This effect thus further enhances the cooling function of the aerosol-cooling element.

Furthermore, the aerosol-cooling element and the aerosol-generating article according to the invention may be manufactured in a continuous process, and the production thereof may be conveniently achieved at high speed and incorporated into existing production lines for manufacturing heated aerosol-generating articles, without requiring substantial modifications to the manufacturing equipment.

The aerosol-cooling element may be made of a material having a relatively high heat capacity, such that the aerosol-cooling element is capable of absorbing the thermal energy carried by the aerosol flowing through the article without causing a substantial increase in the temperature of the aerosol-cooling element. For example, the aerosol-cooling element may be made from cellulose-based compounds, including thermoplastic paper compounds. As another example, the aerosol-cooling element may be made of polylactic acid (PLA) or Polyhydroxyalkanoate (PHA).

The at least one elongate protrusion may be made of the same material as the rest of the aerosol-cooling element. For example, the at least one elongated protrusion may be made of a cellulose-based compound, including a thermoplastic paper compound. As another example, the at least one elongated protrusion may be made of polylactic acid (PLA) or Polyhydroxyalkanoate (PHA). The at least one elongated protrusion may be made by injection molding or other extrusion techniques.

The aerosol-cooling element may have a length of about 5mm to about 35 mm. In some embodiments, the aerosol-cooling element has a length of about 5 millimeters to about 25 millimeters, or about 5 millimeters to about 20 millimeters, or about 5 millimeters to about 19 millimeters.

Preferably, the aerosol-cooling element has a length of at least about 8 mm. More preferably, the aerosol-cooling element has a length of at least about 9 mm. The length of the aerosol-cooling element is preferably less than or equal to about 30 millimeters, or about 8 millimeters to about 25 millimeters, or about 8 millimeters to about 20 millimeters, or about 8 millimeters to about 19 millimeters. More preferably, the aerosol-cooling element has a length of less than or equal to about 25 millimeters. Even more preferably, the aerosol-cooling element has a length of less than or equal to about 20 millimeters. In a particularly preferred embodiment, the aerosol-cooling element has a length of less than or equal to 19 mm.

In preferred embodiments, the aerosol-cooling element has a length of from about 8mm to about 30mm, or from about 8mm to about 25mm, or from about 8mm to about 20 mm, or from about 8mm to about 19mm, more preferably from about 9mm to about 30mm, or from about 9mm to about 25mm, or from about 9mm to about 20 mm, or from about 9mm to about 19 mm.

Preferably, the peripheral wall of the hollow tubular section has a thickness of at least about 0.2 mm. More preferably, the peripheral wall of the hollow tubular section has a thickness of at least about 0.5 mm. Even more preferably, the peripheral wall of the hollow tubular section has a thickness of at least about 1 millimeter. The thickness of the peripheral wall of the hollow tubular section is preferably less than or equal to 3.5 mm. More preferably, the thickness of the peripheral wall of the hollow tubular section is less than or equal to 3 mm. Even more preferably, the thickness of the peripheral wall of the hollow tubular section is less than or equal to about 2.5 millimeters.

In some embodiments, the peripheral wall of the hollow tubular section has a thickness of about 0.2 mm to about 3.5 mm, or about 0.2 mm to about 3 mm, or about 0.2 mm to about 2.5 mm. In other embodiments, the peripheral wall of the hollow tubular section has a thickness of from about 0.5 millimeters to about 3.5 millimeters, or from about 0.5 millimeters to about 3 millimeters, or from about 0.5 millimeters to about 2.5 millimeters. In other embodiments, the peripheral wall of the hollow tubular section has a thickness of from about 1 millimeter to about 3.5 millimeters, or from about 1 millimeter to about 3 millimeters, or from about 1 millimeter to about 2.5 millimeters.

In some preferred embodiments, the peripheral wall of the hollow tubular section has a thickness of from about 0.2 mm to about 3.5 mm, more preferably from about 0.5 mm to about 3 mm, even more preferably from about 1mm to about 2.5 mm.

Preferably, the outer diameter of the hollow tubular section is at least about 3 mm. More preferably, the outer diameter of the hollow tubular section is at least about 4 millimeters. Even more preferably, the outer diameter of the hollow tubular section is at least about 5 millimeters. The outer diameter of the hollow tubular section is preferably less than or equal to about 13 millimeters. More preferably, the outer diameter of the hollow tubular section is less than or equal to about 10 millimeters. Even more preferably, the outer diameter of the hollow tubular section is less than or equal to about 8 millimeters.

In some embodiments, the outer diameter of the hollow tubular section is from about 3 millimeters to about 13 millimeters, or from about 3 millimeters to about 10 millimeters, or from about 3 millimeters to about 8 millimeters. In other embodiments, the outer diameter of the hollow tubular section is from about 4 millimeters to about 13 millimeters, or from about 4 millimeters to about 10 millimeters, or from about 4 millimeters to about 8 millimeters. In other embodiments, the outer diameter of the hollow tubular section is from about 5 millimeters to about 13 millimeters, or from about 5 millimeters to about 10 millimeters, or from about 5 millimeters to about 8 millimeters.

In preferred embodiments, the outer diameter of the hollow tubular section is from about 3 mm to about 13 mm, more preferably from about 4mm to about 10mm, even more preferably from about 5mm to about 8 mm. In some embodiments, the outer diameter of the hollow tubular section is from about 4 millimeters to about 8 millimeters.

Preferably, the inner diameter of the hollow tubular section is at least about 2 mm. More preferably, the inner diameter of the hollow tubular section is at least about 3 millimeters. Even more preferably, the inner diameter of the hollow tubular section is at least about 4 millimeters. The inner diameter of the hollow tubular section is preferably less than or equal to about 10 millimeters. More preferably, the inner diameter of the hollow tubular section is less than or equal to about 7.5 millimeters. Even more preferably, the inner diameter of the hollow tubular section is less than or equal to about 6 millimeters.

In some embodiments, the inner diameter of the hollow tubular section is from about 2 millimeters to about 10 millimeters, or from about 2 millimeters to about 7.5 millimeters, or from about 2 millimeters to about 6 millimeters. In other embodiments, the inner diameter of the hollow tubular section is from about 3 millimeters to about 10 millimeters, or from about 3 millimeters to about 7.5 millimeters, or from about 3 millimeters to about 6 millimeters. In other embodiments, the inner diameter of the hollow tubular section is from about 4 millimeters to about 10 millimeters, or from about 4 millimeters to about 7.5 millimeters, or from about 4 millimeters to about 6 millimeters.

In preferred embodiments, the hollow tubular section has an inner diameter of from about 2 mm to about 10mm, more preferably from about 3 mm to about 7.5 mm, even more preferably from about 4mm to about 6 mm. In some embodiments, the hollow tubular section has an inner diameter of about 3 millimeters to about 7.5 millimeters.

In some preferred embodiments, the at least one elongated protrusion extends in a radial direction from the peripheral wall towards the central axis of the hollow tubular section. By extending in radial direction of the hollow tubular section of the aerosol-cooling element, the at least one elongated protrusion disturbs and blocks the incoming flowing aerosol as much as possible in order to promote turbulence in the flowing aerosol. As mentioned above, the turbulence contributes to the cooling effect provided by the aerosol-cooling element.

In some preferred embodiments, the height of the at least one elongated protrusion varies between the upstream position and the downstream position. Such "height of the at least one elongated protrusion" refers to the vertical distance from the interior of the peripheral wall of the hollow tubular section through which the elongated protrusion extends. In such embodiments, the at least one elongated protrusion may have any profile, wherein the protrusion may extend further into the interior of the hollow tubular section at certain portions of the protrusion than other portions of the protrusion.

In some preferred embodiments, the height of the at least one elongate projection decreases between one and the other of the upstream and downstream positions.

In some preferred embodiments, the ratio of the maximum height of the at least one elongate protrusion to the inner diameter of the aerosol-cooling element is at least 0.1. More preferably, the ratio of the maximum height of the at least one elongate protrusion to the inner diameter of the aerosol-cooling element is at least 0.25. Even more preferably, the ratio of the maximum height of the at least one elongated protrusion to the inner diameter of the aerosol-cooling element is at least 0.33 (one third). The term "maximum height" means that the height of a portion of at least one elongated protrusion is greater than the height of any other portion of at least one elongated protrusion.

In some preferred embodiments, the ratio of the maximum height of the at least one elongated protrusion to the inner diameter of the aerosol-cooling element is less than or equal to 0.75. More preferably, the ratio of the maximum height of the at least one elongated protrusion to the inner diameter of the aerosol-cooling element is less than or equal to 0.6. Even more preferably, the ratio of the maximum height of the at least one elongated protrusion to the inner diameter of the aerosol-cooling element is less than or equal to 0.5.

In some preferred embodiments, the ratio of the maximum height of the at least one elongated protrusion to the inner diameter of the aerosol-cooling element is between 0.1 and 0.75. More preferably, the ratio of the maximum height of the at least one elongated protrusion to the inner diameter of the aerosol-cooling element is between 0.25 and 0.6. Even more preferably, the ratio of the maximum height of the at least one elongated protrusion to the inner diameter of the aerosol-cooling element is between 0.33 (one third) and 0.5.

The at least one elongated protrusion may have a fin-like profile, a tapered profile, a curved profile, or an undulating profile when viewed from the side.

In some preferred embodiments, the at least one elongate protrusion comprises (or is) a deflecting fin configured to change the flow direction of the aerosol flowing from the upstream end to the downstream end of the hollow tubular section. "fins" refers to flat, thin protruding surfaces.

In a preferred embodiment, the at least one elongated protrusion comprises a plurality of deflecting fins. In such preferred embodiments, the plurality of deflecting fins includes at least two deflecting fins. More preferably, the plurality of deflecting fins includes at least four deflecting fins. Even more preferably, the plurality of deflecting fins comprises at least six deflecting fins.

In some preferred embodiments, the deflecting fin comprises opposing first and second surfaces, wherein an angle formed between a reference plane at the upstream location and the first surface of the deflecting fin is different from an angle formed between a reference plane at the downstream location and the first surface of the deflecting fin, the reference plane being parallel to the longitudinal axis and dividing the interior volume of the hollow tubular section into two portions.

In some preferred embodiments, the deflecting fins are twisted along the length of the hollow tubular section. The term "twist" refers to the fact that the profile of the deflecting fin is bent or curled about a reference point or line along the length of the deflecting fin. The deflecting fins may take a helical or spiral form or shape as they extend along the length of the aerosol-cooling element. Such a spiral or helical shape is optimal for imposing turbulence in the flowing aerosol, which in turn enhances the cooling effect provided by the aerosol-cooling element. The term "helical" refers to an element having a helical or spiral-like profile or shape.

In some preferred embodiments, the radial position or circumferential position of at least one elongated protrusion or a portion thereof varies between its upstream position and its downstream position. In such embodiments, the at least one elongated protrusion may not follow a straight line when viewed from above or below. In such embodiments, the base of the at least one elongated protrusion may trace a curved profile, an undulating profile, or any other profile that transitions parallel to the longitudinal axis of the hollow tubular section of the aerosol-cooling element along the inner surface of the peripheral wall.

In some preferred embodiments, the height of the at least one elongated protrusion is less than the radius of the hollow tubular section. Such radius of the hollow tubular section preferably refers to the inner diameter of the hollow tubular section, which is half the inner diameter of the hollow tubular section described above.

In some preferred embodiments, the upstream location is between the upstream end of the hollow tubular section and a midpoint of the hollow tubular section, and wherein the downstream location is between the midpoint of the hollow tubular section and a downstream end of the hollow tubular section. The midpoint of the hollow tubular section refers to the middle of the hollow tubular section, midway between the upstream and downstream ends of the hollow tubular section.

In some preferred embodiments, the upstream position is located one quarter of the length of the aerosol-cooling element facing away from the upstream end. In some other preferred embodiments, the upstream position is located one third of the length of the aerosol-cooling element facing away from the upstream end. In some other preferred embodiments, the upstream position is located at half the length of the aerosol-cooling element facing away from the upstream end.

In some preferred embodiments, the downstream position is located one quarter of the length of the aerosol-cooling element facing away from the downstream end. In some other preferred embodiments, the downstream position is located one third of the length of the aerosol-cooling element facing away from the downstream end. In some other preferred embodiments, the downstream position is located at half the length of the aerosol-cooling element facing away from the downstream end.

In some preferred embodiments, the at least one elongated protrusion extends longitudinally from an upstream end of the hollow tubular section to a downstream end of the hollow tubular section.

In some preferred embodiments, the length of the at least one elongated protrusion is between about 8mm and about 30 mm. More preferably, the length of the at least one elongated protrusion is between about 9mm and about 19 mm. Even more preferably, the at least one elongated protrusion is between about 10mm and about 15 mm.

In some preferred embodiments, the ratio of the length of the at least one elongate protrusion to the length of the aerosol-cooling element is at least 0.25. More preferably, the ratio of the length of the at least one elongate protrusion to the length of the aerosol-cooling element is at least 0.33 (one third). Even more preferably, the ratio of the length of the at least one elongated protrusion to the length of the aerosol-cooling element is at least 0.5.

In some preferred embodiments, the ratio of the length of the at least one elongated protrusion to the length of the aerosol-cooling element is less than or equal to 1. More preferably, the ratio of the length of the at least one elongated protrusion to the length of the aerosol-cooling element is less than or equal to 0.75. Even more preferably, the ratio of the length of the at least one elongated protrusion to the length of the aerosol-cooling element is less than or equal to 0.5.

In some preferred embodiments, the ratio of the length of the at least one elongated protrusion to the length of the aerosol-cooling element is between 0.25 and 1. More preferably, the ratio of the length of the at least one elongate protrusion to the length of the aerosol-cooling element is between 0.25 and 0.75.

In some preferred embodiments, the at least one elongated protrusion has a thickness between about 0.1mm and about 1 mm. More preferably, the at least one elongated protrusion has a thickness between about 0.25mm and about 0.75 mm. Even more preferably, the thickness of the at least one elongated protrusion is between about 0.4mm and about 0.6 mm.

In some preferred embodiments, the thickness of the at least one elongated protrusion is about 0.1 mm. More preferably, the thickness of the at least one elongated protrusion is about 0.25 mm. Even more preferably, the thickness of the at least one elongated protrusion is about 0.4 mm. In some preferred embodiments, the thickness of the at least one elongated protrusion is about 0.6 mm. More preferably, the thickness of the at least one elongated protrusion is about 0.75 mm. Even more preferably, the thickness of the at least one elongated protrusion is about 1 mm.

Preferably, the thickness of the at least one elongated protrusion is less than 20% of the length of the at least one elongated protrusion. More preferably, the thickness of the at least one elongated protrusion is less than 10% of the length of the at least one elongated protrusion. Even more preferably, the thickness of the at least one elongated protrusion is less than 5% of the length of the at least one elongated protrusion.

In some preferred embodiments, the at least one elongated protrusion comprises a plurality of elongated protrusions radially distributed on the peripheral wall. In such preferred embodiments, the plurality of elongated protrusions are evenly (or uniformly) distributed on the peripheral wall in such a manner that the elongated protrusions are equally spaced from each other.

In some preferred embodiments, the at least one elongated protrusion comprises a plurality of elongated protrusions. Preferably, the plurality of elongated protrusions includes at least two elongated protrusions. More preferably, the plurality of elongated protrusions comprises at least four elongated protrusions. Even more preferably, the plurality of elongated protrusions comprises at least six elongated protrusions.

In some preferred embodiments, the at least one elongated protrusion comprises a plurality of elongated protrusions axially distributed at the same radial or circumferential location on the peripheral wall.

In some preferred embodiments, the plurality of elongated protrusions are evenly (or uniformly) distributed on the perimeter wall. This means that the plurality of elongate protrusions are evenly (or uniformly) spaced apart on the peripheral wall. In other embodiments, the plurality of elongated protrusions are spaced apart from each other by different distances.

In some preferred embodiments, the elongated protrusions have substantially the same shape as each other.

The present invention relates to an aerosol-generating article for generating an aerosol when heated. An aerosol-generating article comprises a rod of aerosol-generating substrate. As mentioned above, the aerosol-generating article may comprise a first aerosol-cooling element according to the first aspect of the present disclosure, which is positioned downstream of the rod of aerosol-generating substrate.

According to a second aspect of the present disclosure, there is provided an aerosol-generating article for generating an aerosol when heated. An aerosol-generating article comprises a rod of aerosol-generating substrate. As mentioned above, the aerosol-generating article comprises a first aerosol-cooling element according to the first aspect of the present disclosure, which is positioned downstream of the rod of aerosol-generating substrate.

In some embodiments, the aerosol-generating article may further comprise a hollow tubular support element positioned immediately downstream of the rod of aerosol-generating substrate.

In some embodiments, the aerosol-generating article may further comprise a second aerosol-cooling element located downstream of the hollow tubular support element, wherein the first aerosol-cooling element is positioned downstream of the second aerosol-cooling element and extends all the way to the downstream end of the aerosol-generating article.

In a preferred embodiment, the cavity defined by the first aerosol-cooling element defines a mouth end cavity at the downstream end of the aerosol-generating article.

As briefly mentioned above, the aerosol-generating article may comprise an additional component between the hollow tubular support element and the aerosol-cooling element, which in some embodiments may be a further aerosol-cooling element (also referred to herein as a "secondary" or "second" aerosol-cooling element) adapted to initiate cooling of a gas stream entering from the aerosol-generating substrate so as to promote condensation of compounds released from the substrate such that they condense to form an aerosol. In some embodiments, the secondary aerosol-cooling element may be in the form of a gathered, optionally crimped, sheet of polymeric material, such as polylactic acid (PLA), which defines a plurality of longitudinally extending channels. In practice, a sheet of PLA may be "crimped" to form substantially parallel ridges or corrugations. The crimped PLA sheet may then be gathered, convoluted, pleated, or folded, or otherwise compressed or shrunk substantially transverse to the longitudinal axis such that the substantially parallel ridges or corrugations extend in the longitudinal direction. Without wishing to be bound by theory, one such gathered sheet of crimped polymeric material may essentially act as a heat exchanger.

Preferably, the length of the further aerosol-cooling element is at least about 4 mm. More preferably, the length of the other aerosol-cooling element is at least about 6 mm. Even more preferably, the length of the other aerosol-cooling element is at least about 9 mm. The length of the other aerosol-cooling elements is preferably less than or equal to about 25 mm. More preferably, the length of the other aerosol-cooling element is preferably less than or equal to about 20 mm. Even more preferably, the length of the other aerosol-cooling element is preferably less than or equal to about 15 mm.

In some embodiments, the other aerosol-cooling element has a length of about 4mm to about 25mm, or about 4mm to about 20 mm, or about 4mm to about 15 mm. In other embodiments, the other aerosol-cooling element has a length of about 6 millimeters to about 25 millimeters, or about 6 millimeters to about 20 millimeters, or about 6 millimeters to about 15 millimeters. In other embodiments, the other aerosol-cooling element has a length of about 9 millimeters to about 25 millimeters, or about 9 millimeters to about 20 millimeters, or about 9 millimeters to about 15 millimeters.

In some preferred embodiments, the other aerosol-cooling element has a length of about 4mm to about 25mm, more preferably about 6mm to about 20 mm, about 9mm to about 15 mm.

As briefly mentioned above, aerosol-generating articles according to the present invention incorporate a rod of aerosol-generating substrate and a hollow tubular support element positioned immediately downstream of the rod of aerosol-generating substrate. Furthermore, the aerosol-generating article of the present invention may comprise an aerosol-cooling element downstream of the hollow tubular support element.

In contrast to existing aerosol-generating articles, in an article according to the invention the aerosol-cooling element may extend all the way to the downstream end of the aerosol-generating article. In other words, the aerosol-cooling element may define the mouth end portion of the article and may be drawn by the consumer during use.

The total length of the aerosol-generating article is preferably at least about 35 mm. More preferably, the total length of the aerosol-generating article is at least about 40 mm. Even more preferably, the total length of the aerosol-generating article is at least about 45 mm. Additionally or alternatively, the total length of the aerosol-generating article is preferably less than or equal to about 100 millimeters. More preferably, the total length of the aerosol-generating article is less than or equal to about 80 mm. Even more preferably, the aerosol-generating article has an overall length of less than or equal to about 75 millimeters. Most preferably, the total length of the aerosol-generating article is less than or equal to about 70 mm.

In some embodiments, the aerosol-generating article has an overall length of from about 35 millimeters to about 100 millimeters, or from about 35 millimeters to about 80 millimeters, or from about 35 millimeters to about 75 millimeters, or from about 35 millimeters to about 70 millimeters. In other embodiments, the aerosol-generating article has an overall length of from about 40 millimeters to about 100 millimeters, or from about 40 millimeters to about 80 millimeters, or from about 40 millimeters to about 75 millimeters, or from about 40 millimeters to about 70 millimeters. In other embodiments, the aerosol-generating article has an overall length of from about 45 millimeters to about 100 millimeters, or from about 45 millimeters to about 80 millimeters, or from about 45 millimeters to about 75 millimeters, or from about 45 millimeters to about 70 millimeters.

In particularly preferred embodiments, the total length of the aerosol-generating article is from about 35 mm to about 80 mm, more preferably from about 40 mm to about 75mm, even more preferably from about 45 mm to about 70 mm.

Aerosol-generating articles according to the present invention comprise an aerosol-generating substrate which may be provided in the form of a rod defined by a wrapper.

The outer diameter of the rod of aerosol-generating substrate is preferably approximately equal to the outer diameter of the aerosol-generating article.

Preferably, the rod of aerosol-generating substrate has an outer diameter of at least 5 millimetres. The rod of aerosol-generating substrate may have an outer diameter of between about 5 millimetres and about 12 millimetres, for example between about 5 millimetres and about 10 millimetres, or between about 5 millimetres and about 8 millimetres, or between about 6 millimetres and about 12 millimetres, or between about 6 millimetres and 10 millimetres, or between about 6 millimetres and about 8 millimetres. In a preferred embodiment, the rod of aerosol-generating substrate has an outer diameter of 7.2 millimetres.

The rod of aerosol-generating substrate may have a length of between about 5 millimetres and about 100 millimetres. Preferably, the rod of aerosol-generating substrate has a length of at least about 5mm, more preferably at least about 7 mm. In addition, or as an alternative, the rod of aerosol-generating substrate preferably has a length of less than about 100 millimetres, more preferably less than about 80 millimetres, even more preferably less than about 65 millimetres, most preferably less than or equal to about 50 millimetres. In a particularly preferred embodiment, the rod of aerosol-generating substrate has a length of less than or equal to about 35 millimetres, more preferably less than or equal to 25 millimetres, even more preferably less than or equal to about 20 millimetres. In one embodiment, the rod of aerosol-generating substrate may have a length of about 10 millimetres. In a preferred embodiment, the rod of aerosol-generating substrate has a length of about 12 mm.

In some embodiments, the rod of aerosol-generating substrate has a length of from about 5mm to about 80 mm, or from about 5mm to about 65 mm, or from about 5mm to about 50 mm. In other embodiments, the rod of aerosol-generating substrate has a length of from about 7 mm to about 100 mm, or from about 7 mm to about 80 mm, or from about 7 mm to about 65 mm, or from about 7 mm to about 50 mm. In other embodiments, the rod of aerosol-generating substrate has a length of from about 10mm to about 100 mm, or from about 10mm to about 80 mm, or from about 10mm to about 65 mm, or from about 10mm to about 50 mm.

Preferably, the rod of aerosol-generating substrate has a substantially uniform cross-section along the length of the rod. It is particularly preferred that the rod of aerosol-generating substrate has a substantially circular cross-section.

In a preferred embodiment, the aerosol-generating substrate comprises one or more gathered sheets of homogenized tobacco material. Preferably, the one or more sheets of homogenized tobacco material are textured. As used herein, the term "textured sheet" means a sheet that has been curled, embossed, gravure, perforated, or otherwise deformed. The textured sheet of homogenized tobacco material for use in the present invention may comprise a plurality of spaced indentations, protrusions, perforations or a combination thereof. According to a particularly preferred embodiment of the invention, the rod of aerosol-generating substrate comprises a gathered crimped sheet of homogenized tobacco material defined by a wrapper.

As used herein, the term "crimped sheet" is intended to be synonymous with the term "corrugated sheet" and refers to a sheet having a plurality of substantially parallel ridges or corrugations. Preferably, the crimped sheet of homogenized tobacco material has a plurality of ridges or corrugations substantially parallel to the cylindrical axis of the rod according to the invention. This advantageously promotes the gathering of the crimped sheet of homogenized tobacco material to form a rod. It will be understood, however, that the crimped sheet of homogenized tobacco material for use in the invention may alternatively or additionally have a plurality of substantially parallel ridges or corrugations disposed at acute or obtuse angles to the cylindrical axis of the rod. The sheet of homogenized tobacco material used in the rod of the article of the invention may be textured substantially uniformly over substantially its entire surface. For example, a crimped sheet of homogenized tobacco material for making rods for aerosol-generating articles according to the invention may comprise a plurality of substantially parallel ridges or corrugations that are substantially evenly spaced across the width of the sheet.

The sheet or web of homogenized tobacco material for use in the present invention may have a tobacco content of at least about 40% by weight on a dry weight basis, more preferably at least about 60% by weight on a dry weight basis, more preferably at least about 70% by weight on a dry weight basis, most preferably at least about 90% by weight on a dry weight basis.

The sheet or web of homogenized tobacco material for use in the aerosol-generating substrate may comprise one or more intrinsic binders (i.e. tobacco endogenous binders), one or more extrinsic binders (i.e. tobacco exogenous binders) or a combination thereof to aid in the agglomeration of particulate tobacco. Alternatively or additionally, the sheet of homogenized tobacco material used in the aerosol-generating substrate may comprise other additives including, but not limited to, tobacco and non-tobacco fibres, aerosol-formers, humectants, plasticisers, flavourants, fillers, aqueous and non-aqueous solvents and combinations thereof.

Suitable external binders for inclusion in sheets or webs of homogenized tobacco material for use in aerosol-generating substrates are known in the art and include, but are not limited to: gums such as guar gum, xanthan gum, gum arabic and locust bean gum; cellulose binders such as hydroxypropyl cellulose, carboxymethyl cellulose, hydroxyethyl cellulose, methyl cellulose and ethyl cellulose; polysaccharides, such as starch; organic acids such as alginic acid; conjugate base salts of organic acids, such as sodium alginate, agar, and pectin; and combinations thereof.

Suitable non-tobacco fibres for inclusion in a sheet or web of homogenized tobacco material for use in an aerosol-generating substrate are known in the art and include, but are not limited to: cellulose fibers; softwood fibers; hardwood fibers; jute fibers and combinations thereof. Prior to inclusion in the sheet of homogenized tobacco material for use in an aerosol-generating substrate, the non-tobacco fibres may be treated by suitable processes known in the art including, but not limited to: mechanical pulping, refining, chemical pulping, bleaching, kraft pulping, and combinations thereof.

Preferably, the sheet or web of homogenized tobacco material comprises an aerosol former. As used herein, the term "aerosol-former" describes any suitable known compound or mixture of compounds that, in use, facilitates the formation of an aerosol and is substantially resistant to thermal degradation at the operating temperature of the aerosol-generating article.

Suitable aerosol-forming agents are known in the art and include, but are not limited to: polyhydric alcohols such as propylene glycol, triethylene glycol, 1, 3-butylene glycol, glycerin; esters of polyhydric alcohols such as monoacetin, diacetin, or triacetin; and fatty acid esters of monocarboxylic, dicarboxylic or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate.

Preferred aerosol formers are polyols or mixtures thereof such as propylene glycol, triethylene glycol, 1, 3-butanediol and most preferably glycerol.

The sheet or web of homogenized tobacco material may comprise a single aerosol former. Alternatively, the sheet or web of homogenized tobacco material may comprise a combination of two or more aerosol-formers.

The sheet or web of homogenized tobacco material has an aerosol former content of greater than 10% by dry weight. Preferably, the sheet or web of homogenized tobacco material has an aerosol former content of greater than 12% by dry weight. More preferably, the sheet or web of homogenized tobacco material has an aerosol former content of greater than 14% by dry weight. Even preferably, the sheet or web of homogenized tobacco material has an aerosol former content of greater than 16% by dry weight.

The sheet of homogenized tobacco material may have an aerosol former content of about 10% to about 30% on a dry weight basis. Preferably, the sheet or web of homogenized tobacco material has an aerosol former content of less than 25% by dry weight.

In a preferred embodiment, the sheet of homogenized tobacco material has an aerosol former content of about 20% by dry weight.

The sheet or web of homogenized tobacco used in the aerosol-generating article of the invention may be manufactured by methods known in the art, for example the method disclosed in international patent application WO-A-2012/164009A 2. In a preferred embodiment, a sheet of homogenized tobacco material for use in an aerosol-generating article is formed from a slurry comprising particulate tobacco, guar gum, cellulose fibres and glycerol by a casting process.

Alternative arrangements of homogenized tobacco material for use in rods in aerosol-generating articles will be known to the skilled person and may comprise a plurality of stacked sheets of homogenized tobacco material, a plurality of elongated tubular elements formed by winding strips of homogenized tobacco material about their longitudinal axis, or the like.

As a further alternative, the rod of aerosol-generating substrate may comprise a non-tobacco based nicotine-containing material, such as a sheet of absorbent non-tobacco material loaded with nicotine (e.g. in the form of a nicotine salt) and an aerosol-former. Examples of such strips are described in international application WO-A-2015/052652. Additionally or alternatively, the rod of aerosol-generating substrate may comprise non-tobacco plant material, for example aromatic non-tobacco plant material.

In the rod of aerosol-generating substrate of the article according to the invention, the aerosol-generating substrate is preferably defined by a wrapper. The wrapper may be formed from a porous or non-porous sheet material. The wrapper may be formed from any suitable material or combination of materials. Preferably, the wrapper is a paper wrapper.

As mentioned above, the tubular support element may be provided at a position downstream of the rod of aerosol-generating substrate. The tubular support element includes a cylindrical peripheral wall and defines a gas flow conduit extending longitudinally from an upstream end of the tubular support element to a downstream end of the tubular support element. Thus, the tubular support element establishes fluid communication between the rod of aerosol-generating substrate and one or more components of the article further downstream.

In more detail, the tubular support element is longitudinally aligned with the strip and arranged immediately downstream of the strip. In the context of the present invention, the expression "immediately downstream of the rod" means that the tubular support element and the rod are in contact with each other or in close proximity to each other such that, when receiving an article for use in an aerosol-generating device adapted to heat an aerosol-generating substrate (e.g. an aerosol-generating device comprising a heating element inserted into the rod), the tubular support element is effective to provide support for the rod with little deformation of the aerosol-generating article, little displacement of the rod, or both. Thus, in practice, as used herein with reference to the invention, the expression "immediately downstream of the strip" is used to indicate that the minimum longitudinal distance between the downstream end surface of the strip and the upstream end surface of the peripheral wall of the tubular support element is less than 1mm, preferably less than 0.5 mm, even more preferably less than 0.25 mm. In a particularly preferred embodiment, the upstream end surface of the peripheral wall of the tubular support element directly contacts the downstream end surface of the rod of aerosol-generating substrate.

Thus, the tubular support element may effectively hold the rod of aerosol-generating substrate at a predetermined distance from the downstream end of the aerosol-generating article. In addition, the tubular support element imparts structural strength to the aerosol-generating article such that it can be easily handled by a consumer and can be conveniently inserted into an aerosol-generating device for use.

The tubular support element may be made of a porous material or of a gas impermeable material. Suitable examples of porous materials include, but are not limited to, cellulose acetate and many other porous polymeric materials known to those skilled in the art. Suitable examples of gas impermeable materials include, but are not limited to, non-porous polymeric materials, with bioplastics being particularly preferred.

In a preferred embodiment, the tubular support element is a hollow cellulose acetate tube.

During use, a thermal gradient is established along the airflow conduit of the tubular support element. In practice, the temperature difference is provided such that the temperature of the volatile aerosol component entering the tubular support element at the downstream end of the rod of aerosol-generating substrate is generally greater than the temperature of the volatile aerosol component exiting the tubular support element at the downstream end of the tubular support element. However, this is generally not sufficient to sufficiently cool the volatile aerosol components.

The thickness of the cylindrical peripheral wall of the hollow tubular support element is preferably less than or equal to 2 mm. More preferably, the thickness of the cylindrical peripheral wall is less than or equal to 1.5 mm. Even more preferably, the thickness of the cylindrical peripheral wall is less than or equal to 1 mm.

The cylindrical peripheral wall of the hollow tubular support element has a thickness of at least 0.2 mm. More preferably, the thickness of the cylindrical peripheral wall is at least 0.4 mm. Even more preferably, the thickness of the cylindrical peripheral wall is at least 0.6 mm.

In some embodiments, the thickness of the cylindrical peripheral wall of the hollow tubular section is preferably from about 0.2 mm to about 2 mm, more preferably from about 0.4mm to about 1.5 mm, even more preferably from about 0.6mm to about 1 mm.

Thus, at the upstream end, the cylindrical peripheral wall presents an end surface adapted to abut a peripheral portion of the rod of aerosol-generating substrate. In some embodiments, the upstream end surface of the perimeter wall may have a substantially flat profile. Thus, it may contact the downstream end surface of the strip substantially in its entirety. In an alternative embodiment, the upstream end surface of the perimeter wall has a non-planar profile, such as an inclined profile or a curved profile, such that the perimeter wall contacts the strip only at its outermost peripheral edge, with some space provided between the downstream end surface of the strip and the end surface of the perimeter wall at the inner periphery of the perimeter wall.

Preferably, the hollow tubular support element has a length of at least about 10 mm. More preferably, the hollow tubular support element has a length of at least about 15 millimeters. Even more preferably, the hollow tubular support element has a length of at least about 20 millimeters.

The length of the hollow tubular support element is preferably less than or equal to about 60 millimeters. More preferably, the hollow tubular support element has a length of less than or equal to about 50 millimeters. Even more preferably, the hollow tubular support element has a length of less than or equal to about 40 millimeters.

In some embodiments, the hollow tubular support element has a length of about 10 millimeters to about 60 millimeters, or about 10 millimeters to about 50 millimeters, or about 10 millimeters to about 40 millimeters. In other embodiments, the hollow tubular support element has a length of about 15 millimeters to about 60 millimeters, or about 15 millimeters to about 50 millimeters, or about 15 millimeters to about 40 millimeters. In other embodiments, the hollow tubular support element has a length of about 20 millimeters to about 60 millimeters, or about 20 millimeters to about 50 millimeters, or about 20 millimeters to about 40 millimeters.

In some preferred embodiments, the hollow tubular support element has a length of about 10mm to about 60 mm, more preferably about 15mm to about 50 mm, even more preferably about 20 mm to about 40 mm.

As briefly mentioned above, an aerosol-generating article according to the invention comprises an aerosol-cooling element longitudinally aligned with the rod and the hollow tubular support element and positioned downstream of the hollow tubular support element.

In some embodiments, the aerosol-cooling element is positioned immediately downstream of the hollow tubular support element. As used herein with respect to the present invention, the expression "immediately downstream of the hollow tubular support element" means that the aerosol-cooling elements are in contact with each other or in close proximity to each other. In practice, the expression "immediately downstream of the hollow tubular support element" is used to indicate that the minimum longitudinal distance between the downstream end surface of the hollow tubular support element and the upstream end surface of the peripheral wall of the aerosol-cooling element is less than 1mm, preferably less than 0.5 mm, even more preferably less than 0.25 mm. In a particularly preferred embodiment, the upstream end surface of the aerosol-cooling element directly contacts the downstream end surface of the peripheral wall of the hollow tubular support element.

In other embodiments, the aerosol-generating article may comprise one or more additional components between the hollow tubular support element and the aerosol-cooling element.

For example, the aerosol-generating article may comprise a filter segment of filter material capable of removing particulate components, gaseous components, or a combination thereof. Suitable filter materials are known in the art and include, but are not limited to: fibrous filter materials such as cellulose acetate tow, viscose, Polyhydroxyalkanoate (PHA) fibers, polylactic acid (PLA) fibers and paper; adsorbents such as activated alumina, zeolites, molecular sieves, and silica gel; and combinations thereof. In addition, the filter segment of filter material may further comprise one or more aerosol modifiers. Suitable aerosol modifiers are known in the art and include, but are not limited to, flavorants, such as, for example, menthol. The length of the filter segment of filter material may be from about 4mm to about 25 mm. Preferably, the filter segments of filter material are at least about 6mm in length, more preferably at least about 8mm in length. The length of the filter segment of filter material is preferably less than or equal to about 25 millimeters, more preferably less than or equal to about 20 millimeters, and even more preferably less than or equal to about 15 millimeters. In particularly preferred embodiments, the length of the filter segment of filter material is less than or equal to about 10 millimeters. In an exemplary embodiment, the filter segment of filter material is about 5 millimeters in length. In an exemplary embodiment, the length of the mouthpiece is about 7 millimeters.

The components of the aerosol-generating article according to the invention may be defined solely by such a package. The wrapper may be formed from a porous or non-porous sheet material. The wrapper may be formed from any suitable material or combination of materials. Preferably, the wrapper is a paper wrapper. However, two or more parts may also be defined by the same wrapper. Furthermore, the rod and other components of the aerosol-generating substrate are typically assembled within a single package. For example, in an embodiment, an aerosol-generating article comprises a rod of aerosol-generating substrate as described above, a tubular support element, an aerosol-cooling element, and an outer wrapper defining the rod, the support element and the aerosol-cooling element, arranged in linear order. In another embodiment, an aerosol-generating article comprises a rod of aerosol-generating substrate as described above, a secondary aerosol-cooling element, an aerosol-cooling element, and an outer wrapper defining the rod, a support element and the aerosol-cooling element, arranged in linear order.

In some embodiments, the aerosol-generating article comprises a ventilation zone at a location along the aerosol-cooling element. Preferably, the aerosol-generating article comprises a ventilation zone at a location along the length of the aerosol-cooling element.

In some embodiments, the ventilation zone is disposed at a location along the lumen of the hollow tubular section. Thus, fluid communication is established between the external environment and the cavity such that when the aerosol-generating article is inhaled by a consumer, some ambient air is drawn into the cavity through the vent holes formed through the peripheral wall of the hollow tubular section. This is advantageous because by mixing ambient air with the incoming aerosol stream, the temperature of the aerosol can be reduced and condensation or growth of aerosol particles, or both, can be facilitated. Likewise, the flow of ambient air through the peripheral wall of the aerosol-cooling element may further facilitate maintaining the temperature of the peripheral wall below a desired threshold.

In a particularly preferred embodiment, the ventilation zone comprises a plurality of holes extending through the peripheral wall, so that an inclined air flow duct is formed connecting the external environment with the cavity of the hollow tubular section. This may in particular help to keep the temperature of the peripheral wall of the aerosol-cooling element below a desired threshold.

An aerosol-generating article as described above may be used in an electrically operated aerosol-generating device as part of an aerosol-generating system according to the present disclosure or another aspect of the invention. One such aerosol-generating system comprises an aerosol-generating article as described above and an electrically operated aerosol-generating device comprising a heating element and an elongate heating chamber configured to receive the aerosol-generating article such that a rod of aerosol-generating substrate is heated in the heating chamber. Preferably, the heating element comprises a heater blade or heater needle adapted to be inserted into a rod of aerosol-generating substrate when the aerosol-generating article is received into the heating chamber.

Drawings

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

figure 1 shows a front perspective view of an aerosol-cooling element according to the invention;

figure 2 shows a schematic side section view of an aerosol-cooling element according to the invention;

figure 3 shows a schematic cross-sectional view of the aerosol-cooling element of figure 2 taken along a mid-plane T-T located at the aerosol-cooling element;

figure 4 shows a side cross-sectional view of an aerosol-generating article comprising an aerosol-cooling element according to the present invention; and is

Figure 5 shows a schematic side cross-sectional view of an aerosol-generating system comprising an electrically operated aerosol-generating device and the aerosol-generating article shown in figure 4.

Detailed Description

The aerosol-cooling element 16 shown in fig. 1 comprises a hollow tubular section 8 comprising a peripheral wall 24 having a thickness of about 0.5 mm and defining a cavity 28. Furthermore, the hollow tubular section 8 comprises a plurality of elongated protrusions 26 extending from the peripheral wall 24 into the interior of the hollow tubular section 22. Each of the elongate projections 26 extends from an upstream end of the hollow tubular section 8 to a downstream end of the hollow tubular section 8 and into the interior of the hollow tubular section 23.

As shown in fig. 1, the plurality of elongated projections 26 includes four deflecting fins. Four deflecting fins 26 are evenly radially distributed within the interior of the aerosol-cooling element. This means that the deflecting fins 26 are evenly spaced radially from each other. As shown in fig. 2, the deflecting fin 26 is twisted between the upstream end of the hollow tubular section 8 and the downstream end of the hollow tubular section 8. As shown in fig. 2, the circumferential position of the elongate protrusions 26 varies along the length of the aerosol-cooling element. As shown in fig. 2, the circumferential position of the elongated protrusion at the midpoint of the aerosol-cooling element is different from the circumferential position of the elongated protrusion at the downstream end of the aerosol-cooling element, as shown by the cross-section of the deflecting fin shown in dashed lines.

The aerosol-generating article 10 shown in figure 4 comprises a rod 12 of aerosol-generating substrate according to the first embodiment of the invention, a tubular support element 14 and an aerosol-cooling element 16. The three elements are arranged sequentially and coaxially aligned and are defined by a wrapper 18 to form the aerosol-generating article 10. The aerosol-generating article 10 has a mouth or downstream end 20 and an upstream end 22 located at the opposite end of the article to the mouth end 20. The aerosol-generating article 10 shown in figure 4 is particularly suitable for use with an electrically operated aerosol-generating device comprising a heater for heating a rod of aerosol-generating substrate.

The rod 12 of aerosol-generating substrate is approximately 12 mm in length and approximately 7 mm in diameter. The strip 12 is cylindrical and has a substantially circular cross-section.

The tubular support element 14 is provided as a hollow cellulose acetate tube. Its length is about 8 mm. The outer diameter of the tubular support element 14 is about 7 mm. The peripheral wall of the tubular support element 14 has a thickness of about 1.85 mm.

Figure 5 shows a portion of an electrically operated aerosol-generating system 200 which utilises a heater blade 210 to heat a rod 12 of aerosol-generating substrate of the aerosol-generating article 10 shown in figure 4. The heater blade 210 is mounted within an aerosol-generating article chamber within the housing of an electrically operated aerosol-generating device 212. The aerosol-generating device 212 defines a plurality of air holes 214 for allowing air to flow to the aerosol-generating article 10, as indicated by the arrows in figure 5. The aerosol-generating device 212 comprises a power supply and electronics not shown in fig. 5.

The aerosol-generating article 10 shown in figure 4 is designed to engage with the aerosol-generating device 212 shown in figure 5 in order to be consumed.

The user inserts the aerosol-generating article 10 into the aerosol-generating device 212 such that the heater blade 210 is inserted into the rod 12 of aerosol-generating substrate. The aerosol-cooling element 16 projects outwardly from the mouth end of the device 212. Once the aerosol-generating article 10 is engaged with the aerosol-generating device 212, a user draws in the aerosol-cooling element 16 at the mouth end of the aerosol-generating article 10 defining the mouthpiece, and the rod 12 of aerosol-generating substrate is heated by the heater blade 210 to a temperature sufficient to generate an aerosol from the rod 12 of aerosol-generating substrate. The aerosol is drawn through the aerosol-cooling element 16 and into the mouth of the user.

It will be appreciated that the aerosol-generating article 10 shown in figure 4 may also be suitable for use with other types of aerosol-generating devices.

Claims

1. An aerosol-generating article for generating an aerosol when heated, the aerosol-generating article comprising:

a rod of aerosol-generating substrate;

a first aerosol-cooling element positioned downstream of the rod of aerosol-generating substrate, the aerosol-cooling element comprising a hollow tubular section comprising a peripheral wall, the hollow tubular section extending along a longitudinal axis and having an upstream end and a downstream end in fluid communication, wherein the hollow tubular section comprises at least one elongate projection extending from the peripheral wall into an interior of the hollow tubular section, the at least one elongate projection extending longitudinally from an upstream location on the peripheral wall to a downstream location on the peripheral wall downstream of the upstream location; and

a wrapper defining a rod of the aerosol-generating substrate and the first aerosol-cooling element.

2. An aerosol-generating article according to claim 1, wherein the at least one elongate projection extends in a radial direction from the peripheral wall towards a central axis of the hollow tubular segment.

3. An aerosol-generating article according to claim 1 or 2, wherein the height of the at least one elongate protrusion varies between the upstream and downstream positions.

4. An aerosol-generating article according to claim 3, wherein the height of the at least one elongate protrusion decreases between one and the other of the upstream and downstream positions.

5. An aerosol-generating article according to any preceding claim, wherein the at least one elongate protrusion is a deflection fin configured to change the direction of flow of aerosol flowing from the upstream end to the downstream end of the hollow tubular segment.

6. An aerosol generating article according to claim 5, wherein the deflection fin comprises opposing first and second surfaces, wherein an angle formed between a reference plane at the upstream location and the first surface of the deflection fin is different from an angle formed between the reference plane at the downstream location and the first surface of the deflection fin, the reference plane being parallel to a longitudinal axis and dividing an interior volume of the hollow tubular section into two portions.

7. An aerosol-generating article according to claim 5, wherein the deflection fin is twisted along the length of the hollow tubular section.

8. An aerosol-generating article according to any preceding claim, wherein the circumferential position of the at least one elongate protrusion varies between its upstream position and its downstream position.

9. An aerosol-generating article according to any preceding claim, wherein the height of the at least one elongate protrusion is less than the radius of the hollow tubular section.

10. An aerosol-generating article according to any preceding claim, wherein the upstream location is located between the upstream end of the hollow tubular segment and a midpoint of the hollow tubular segment, and wherein the downstream location is located between the midpoint of the hollow tubular segment and the downstream end of the hollow tubular segment.

11. An aerosol-generating article according to any one of claims 1 to 9, wherein the at least one elongate projection extends longitudinally from the upstream end of the hollow tubular section to the downstream end of the hollow tubular section.

12. An aerosol-generating article according to any preceding claim, wherein the length of the aerosol-generating article is between 8mm and 30 mm.

13. An aerosol-generating article according to any preceding claim, wherein the thickness of the at least one elongate protrusion is between about 0.1mm and about 1 mm.

14. An aerosol-generating article according to any preceding claim, wherein the at least one elongate projection comprises a plurality of elongate projections radially distributed on the peripheral wall.