CN114901089A

CN114901089A - Aerosol-generating device with ventilation chamber

Info

Publication number: CN114901089A
Application number: CN202080089358.XA
Authority: CN
Inventors: Y·约迪尔; M·明佐尼
Original assignee: Philip Morris Products SA
Current assignee: Philip Morris Products SA
Priority date: 2019-12-23
Filing date: 2020-12-21
Publication date: 2022-08-12
Also published as: US20230027569A1; JP2023508291A; EP4081055A1; WO2021130189A1; KR20220119105A; BR112022012162A2

Abstract

An aerosol-generating device (20) configured to receive an aerosol-generating article (1) is provided. The aerosol-generating device has a distal end and a mouth end (2) and comprises a housing (4) and a heater for heating the aerosol-generating article when the aerosol-generating article is received within a device cavity. The housing includes a peripheral wall (6). The peripheral wall defines a device cavity for removably receiving an aerosol-generating article at the mouth end of the device. The housing also includes a ventilation chamber (28). A ventilation chamber is defined within the peripheral wall. The ventilation chamber is configured to be in fluid communication with an exterior of the aerosol-generating device and an aerosol-generating article received within the device cavity. The ventilation chamber is configured to be in fluid communication with the exterior of the aerosol-generating device through a chamber inlet (24) defined in the housing. The chamber inlet has a cross-sectional area less than the ventilation chamber. The chamber inlet extends between the vent chamber and the mouth end of the aerosol-generating device. The length of the ventilation chamber is less than or equal to 8 mm.

Description

Aerosol-generating device with ventilation chamber

Technical Field

The present invention relates to an aerosol-generating device configured to receive an aerosol-generating article and having a ventilation chamber. The present application also describes an aerosol-generating system comprising such an aerosol-generating device.

Background

Aerosol-generating articles in which an aerosol-forming 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-forming 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-forming 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-forming substrate of a heated aerosol-generating article.

However, when aerosol-generating articles having ventilation apertures (referred to as "ventilation zones") on their outer wrapper are received within known aerosol-generating devices, such ventilation apertures may be exposed to the external environment of the device. The vent orifice can provide beneficial dilution of an aerosol flowing through the article for delivery to a consumer during use of the article within the device, as well as a vent airflow that can reduce the temperature of the generated aerosol.

Exposure of the vent orifice may result in the consumer inadvertently plugging the vent orifice of the article with his fingers or lips during normal use of the aerosol-generating system. This blocking, in turn, can affect the sensory experience of the consumer by increasing the effective resistance to draw of the article and preventing optimal aerosol formation and cooling. It is therefore desirable to provide an aerosol-generating device that addresses at least this problem.

Disclosure of Invention

According to the present invention, there is provided an aerosol-generating device configured to receive an aerosol-generating article. The aerosol-generating device has a distal end and a mouth end, and comprises a housing and a heater for heating the aerosol-generating article when the aerosol-generating article is received within the device cavity. The housing includes a peripheral wall. The peripheral wall defines a device cavity for removably receiving an aerosol-generating article at the mouth end of the device. The housing also includes a ventilation chamber. A ventilation chamber is defined within the peripheral wall. The ventilation chamber is configured to be in fluid communication with an exterior of the aerosol-generating device and an aerosol-generating article received within the device cavity. The ventilation chamber is configured to be in fluid communication with an exterior of the aerosol-generating device through a chamber inlet defined in the housing. The chamber inlet has a cross-sectional area less than the ventilation chamber. The chamber inlet extends between the vent chamber and the mouth end of the aerosol-generating device. The length of the plenum is less than or equal to about 8 mm.

According to the present application, there may be provided an aerosol-generating device configured to receive an aerosol-generating article. The aerosol-generating device may have a distal end and a mouth end. The aerosol-generating device may comprise a housing. The aerosol-generating device may comprise a heater for heating the aerosol-generating article when the aerosol-generating article is received within the device cavity. The housing may include a peripheral wall. The peripheral wall may define a device cavity for removably receiving an aerosol-generating article at a mouth end of the device. The housing may include a ventilation chamber. A vent chamber may be defined within the peripheral wall. The ventilation chamber may be configured to be in fluid communication with the exterior of the aerosol-generating device and the aerosol-generating article received within the device cavity. The ventilation chamber may be configured to be in fluid communication with the exterior of the aerosol-generating device through a chamber inlet defined in the housing. The chamber inlet may have a smaller cross-sectional area than the ventilation chamber.

The aerosol-generating device may comprise a heater for heating the aerosol-forming substrate when the aerosol-generating article is received within the device cavity.

The term "mouth end" refers to the portion of an element or component that is configured to be positioned in or near the mouth of a user during normal use of the element or component. The mouth end may also correspond to the downstream end. For example, the mouth end of the aerosol-generating article may also be the downstream end of the article. The mouth end of the aerosol-generating article or device is configured to be placed in or near the mouth of a consumer during normal use. The mouth end of the aerosol-generating device may also be referred to as the proximal end of the aerosol-generating device. The mouth end of the aerosol-generating device may refer to the mouth end face of the aerosol-generating device configured to receive the aerosol-generating article. Thus, the open end of the device cavity may be defined in the mouth end face of the aerosol-generating device.

By providing a ventilation chamber within the peripheral wall of the aerosol-generating device, the portion of the aerosol-generating article that is received within the cavity of the aerosol-generating device and that is overlapped or surrounded by the ventilation chamber may be cooled during use. The wrapper of the aerosol-generating article may be porous to allow air entering the ventilation chamber to also enter the aerosol-generating article in order to provide such a cooling effect. This cooling effect may also improve the formation and nucleation of an aerosol within the aerosol-generating article during use when the aerosol-generating article is received within an aerosol-generating device. This enhancement of aerosol nucleation may provide an improved sensory experience for the consumer. Furthermore, by providing a relatively short ventilation chamber of less than or equal to about 8mm, a short overlap between the aerosol-generating article and the ventilation chamber of the aerosol-generating device is achieved. Thus, more directional and localised portions of the aerosol-generating article are cooled when received within the device, and so the cooling effect produced by the cooling air entering the ventilation chamber may be more effective on such portions.

Furthermore, during use of the aerosol-generating article, generated aerosol may accumulate within the ventilation chamber. This accumulated aerosol can provide a supplemental source of aerosol for the consumer to inhale during use. This further improves the sensory experience for the user.

During use, the consumer may draw in the aerosol-generating article, preferably the mouth end of the article. Air may flow into the ventilation chamber through the chamber inlet and around the article towards the aerosol-forming substrate of the article. The air stream may flow through the aerosol-forming substrate of the article in order to provide an aerosol to the consumer at the mouth end of the article.

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.

The housing of the aerosol-generating device may extend between the distal end and the mouth end of the device. The housing of the aerosol-generating device may extend from the distal end to the mouth end of the device.

As used herein, the term "longitudinal" refers to a direction corresponding to a major longitudinal axis of an aerosol-generating article or device, which extends between an upstream end and a downstream end of the aerosol-generating article or aerosol-generating device.

As used herein, the terms "upstream" and "downstream" describe the relative position of an aerosol-generating article or a component or part of a component of a device 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 dimension of a component of an aerosol-generating article or device in the longitudinal direction.

As used in this specification, the term "homogenised tobacco material" encompasses any tobacco material formed from the agglomeration of particles of tobacco material. A sheet or web of homogenised tobacco material is formed by agglomerating particulate tobacco obtained by grinding or otherwise powdering one or both of a tobacco lamina and a 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. Sheets of homogenised tobacco material may be produced by casting, extrusion, a papermaking process or any other suitable process known in the art.

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.

The expression "received within" may refer to the fact that a component or element is received completely or partially within another component or element. For example, the expression "the aerosol-generating article is received within the device cavity" means that the aerosol-generating article is received fully or partially within the device cavity of the aerosol-generating article. When the aerosol-generating article is received within the device cavity, the aerosol-generating article may abut the distal end of the device cavity. When the aerosol-generating article is received within the device cavity, the aerosol-generating article may be substantially proximal to the distal end of the device cavity. The distal end of the device lumen may be defined by an end wall.

The length of the device lumen may be between about 10mm and about 50 mm. The length of the device lumen may be between about 20mm and about 40 mm. The length of the device lumen may be between about 25mm and about 30 mm.

The term "mouth end" refers to the portion of an element or component that is configured to be in or near the mouth of a user during normal use. The mouth end may also correspond to the downstream end. For example, the mouth end of the aerosol-generating article may also be the downstream end of the article. The mouth end of the aerosol-generating article or device is configured to be placed in or near the mouth of a consumer during normal use. The mouth end of the aerosol-generating device may also be referred to as the proximal end of the aerosol-generating device. The mouth end of the aerosol-generating device may refer to the mouth end face of the aerosol-generating device configured to receive the aerosol-generating article. Thus, the open end of the device cavity may be defined at the mouth end face of the aerosol-generating device.

The ventilation chamber may preferably be located at a longitudinal position facing away from the mouth end of the aerosol-generating device. Preferably, the ventilation chamber is configured to be in fluid communication with the exterior of the aerosol-generating device via the mouth end of the aerosol-generating device. Preferably, the ventilation chamber is configured to be in fluid communication with the exterior of the aerosol-generating device via a mouth end face of the aerosol-generating device. In other words, the air is configured to enter the ventilation chamber via the mouth end or mouth end face of the aerosol-generating device.

In the present context, the expression "longitudinal position facing away from the mouth end of the aerosol-generating device" refers to a longitudinal position which is not located at the mouth end of the aerosol-generating device. Thus, a longitudinal position facing away from the mouth end of the aerosol-generating device refers to a longitudinal position that is different (or at a distance) from the longitudinal position of the mouth end of the aerosol-generating device.

By providing a ventilation chamber facing away from the mouth end of the aerosol-generating device, the ventilation chamber may form a cavity or space around the aerosol-generating article received within the cavity of the device and facing away from the mouth end of the device. This ventilation chamber is in fluid communication with the exterior of the aerosol-generating article when the aerosol-generating article is received with the article. The exterior of the aerosol-generating article may be defined by the wrapper. The packaging material may be porous. The wrapper may be sufficiently porous to allow air from the ventilation chamber to enter the aerosol-generating article. By allowing air to enter, the ventilation chamber may facilitate cooling of the article, which may enhance nucleation of aerosol particles within the article. When located at a longitudinal position away from the mouth end, the ventilation chamber may be more likely to promote nucleation, as the ventilation chamber is more likely to overlap with a more upstream portion of the aerosol-generating article, closer to where aerosol generation occurs. Thus, such positioning of the ventilation chamber may improve aerosol delivery to the consumer.

In such embodiments, the ventilation chamber has two ends, a first end and a second end. The second end of the plenum is closer to the mouth end of the device than the first end of the plenum. In such embodiments, both ends of the ventilation chamber are located away from the mouth end of the aerosol-generating device. In other words, the second end is not located at the mouth end of the device.

In such embodiments, the chamber inlet may extend between the vent chamber and the mouth end of the aerosol-generating device. The chamber inlet may extend between the second end of the ventilation chamber and the mouth end of the aerosol-generating device.

The second end of the ventilation chamber may be located at least about 1mm from the mouth end (face) of the aerosol-generating device (or the open end of the device cavity). The second end of the ventilation chamber may be located at least about 2mm from the mouth end (face) of the aerosol-generating device. The second end of the ventilation chamber may be located at least about 3mm from the mouth end (face) of the aerosol-generating device.

The first end of the ventilation chamber may be located at least about 10mm from the distal end of the device lumen. The first end of the ventilation chamber may be located at least about 20mm from the distal end of the device lumen. The first end of the ventilation chamber may be located at least about 30mm from the distal end of the device lumen.

The chamber inlet may be a separate element from the device cavity. In other words, the chamber inlet may not be defined by the device cavity, but may instead be defined in the housing. The chamber inlet may be defined in a peripheral wall defining a device cavity. Preferably, the chamber inlet is defined within the thickness of or on the peripheral wall. In other words, the chamber inlet may be defined on a surface (e.g., an inner or interior surface) of the peripheral wall or within the thickness of the peripheral wall at a location between the inner and outer longitudinal surfaces of the peripheral wall.

The chamber inlet enables fluid communication between the exterior of the aerosol-generating device and the ventilation chamber. Thus, air from outside the device may be in fluid communication with the wrapper of the aerosol-generating article when the aerosol-generating article is received within the device. This fluid communication enhances aerosol production by promoting nucleation and cooling of the aerosol produced in the article.

When the aerosol-generating article has a ventilation zone on the wrapper, air entering the ventilation chamber from outside the aerosol-generating device through the chamber inlet may pass through the ventilation zone of the article. This provides ventilation for the aerosol-generating article.

In addition, the generated aerosol may accumulate in the ventilation chamber. This accumulation of aerosol can enhance the consumer experience by providing a supplemental source of aerosol. The consumer may use a supplemental source of such aerosol.

In some embodiments, the chamber inlet may extend between the vent chamber and the mouth end of the aerosol-generating device. This enables air to flow from the exterior of the device to the ventilation chamber through the chamber inlet and minimises the likelihood of the user becoming blocked by fingers when holding the aerosol-generating device, as the chamber inlet will not be located around the periphery of the device housing, but will preferably extend from the mouth end face of the device.

The chamber inlet may extend in any direction from the ventilation chamber so as to establish a fluid connection between the ventilation chamber and the exterior of the device. The chamber inlet may extend substantially in a direction parallel to a longitudinal axis of the aerosol-generating device. The chamber inlet may extend substantially in a direction perpendicular to a longitudinal axis of the aerosol-generating device.

The chamber inlet may have a circular cross-section. The chamber inlet may have an annular cross-section. The chamber inlet may have an annular sector shaped cross-section. "annular sector" means a portion or segment of an annular shape or ring.

The chamber inlet and the ventilation chamber may have the same cross-sectional shape. For example, the plenum may be annular and the plenum inlet may be annular. For example, the ventilation chamber may be circular and the chamber inlet may also be circular. Alternatively, the chamber inlet and the ventilation chamber may have different cross-sectional shapes. For example, the chamber inlet may be circular and the ventilation chamber may be annular.

The cross-sectional area of the chamber inlet may be less than the cross-sectional area of the ventilation chamber. The cross-sectional area of the chamber inlet may vary along the longitudinal direction.

The chamber inlet may be cylindrical or conical.

The cross-sectional area of the chamber inlet may be less than or equal to about 75% of the cross-sectional area of the ventilation lumen. The cross-sectional area of the chamber inlet may be less than or equal to about 50% of the cross-sectional area of the ventilation chamber. The cross-sectional area of the chamber inlet may be less than or equal to about 25% of the cross-sectional area of the ventilation chamber. The cross-sectional area of the chamber inlet may be less than or equal to about 20% of the cross-sectional area of the ventilation lumen. The cross-sectional area of the chamber inlet may be less than or equal to about 10% of the cross-sectional area of the ventilation chamber. The cross-sectional area of the chamber inlet may be less than or equal to about 5% of the cross-sectional area of the ventilation chamber.

The diameter of the chamber inlet may be equal to or greater than about 0.1 mm. The diameter of the chamber inlet may be equal to or greater than about 0.2 mm. The diameter of the chamber inlet may be equal to or greater than about 0.5 mm.

The diameter of the chamber inlet may be equal to or less than about 2 mm. The diameter of the chamber inlet may be equal to or less than about 1.5 mm. The diameter of the chamber inlet may be equal to or less than about 1 mm.

The chamber inlet may be between about 0.1mm and about 2mm in diameter. The chamber inlet may be between about 0.2mm and about 1.5mm in diameter. The chamber inlet may be between about 0.5mm and about 1mm in diameter.

The ratio of the diameter of the chamber inlet to the depth of the ventilation chamber may be equal to or less than about 30. The ratio of the diameter of the chamber inlet to the depth of the ventilation chamber may be equal to or less than about 20. The ratio of the diameter of the chamber inlet to the depth of the ventilation chamber may be equal to or greater than about 15.

The ratio of the diameter of the chamber inlet to the depth of the ventilation chamber may be equal to or greater than about 2. The ratio of the diameter of the chamber inlet to the depth of the ventilation chamber may be equal to or greater than about 5. The ratio of the diameter of the chamber inlet to the depth of the ventilation chamber may be equal to or greater than about 10.

The ratio of the diameter of the chamber inlet to the depth of the ventilation chamber may range between about 2 and about 30. The ratio of the diameter of the chamber inlet to the depth of the ventilation chamber may range between about 5 and about 20. The ratio of the diameter of the chamber inlet to the depth of the ventilation chamber may range between about 10 and about 15.

In the case where the depth of the ventilation chamber varies, the depth of the ventilation chamber may refer to the average depth of the ventilation chamber. In the case where the diameter of the chamber inlet varies, the diameter of the chamber inlet may refer to the average diameter of the chamber inlet.

The length of the chamber inlet may be equal to or greater than about 1 mm. The length of the chamber inlet may be equal to or greater than about 2 mm. The length of the chamber inlet may be equal to or greater than about 3 mm.

The length of the chamber inlet may be equal to or less than about 15 mm. The length of the chamber inlet may be equal to or less than about 10 mm. The length of the chamber inlet may be equal to or less than about 6 mm. The length of the chamber inlet may be equal to or less than about 4 mm.

The chamber inlet may be between about 1mm and about 15mm in length. The chamber inlet may be between about 1mm and about 6mm in length. The chamber inlet may be between about 2mm and about 6mm in length. The chamber inlet may be between about 3mm and about 4mm in length.

The length of the chamber inlet may define the distance of the ventilation chamber from the mouth end of the aerosol-generating device.

There may be multiple chamber inlets. In such embodiments, the chamber inlets may be evenly and radially distributed at the mouth end of the device.

In some embodiments, the thickness of the portion of the peripheral wall defining the ventilation chamber may be different from the thickness of a different portion of the peripheral wall.

In some embodiments, the thickness of the portion of the peripheral wall defining the ventilation chamber may be less than the thickness of a different portion of the peripheral wall. In some embodiments, the portion of the peripheral wall defining the ventilation chamber may have a thickness that is less than the thickness of the remainder of the peripheral wall.

In some embodiments, the thickness of the portion of the peripheral wall defining the ventilation chamber may vary along the longitudinal direction. In such embodiments, the portion of the peripheral wall defining the ventilation chamber may decrease towards the mouth end of the aerosol-generating device. In such embodiments, the portion of the peripheral wall defining the ventilation chamber may increase towards the mouth end of the aerosol-generating device.

The variation in thickness of the peripheral wall enables a ventilation chamber to be defined within the peripheral wall of the device cavity. This change or difference in thickness provides a space between the aerosol-generating article received within the device and the peripheral wall of the device cavity, which in turn enables air to flow between the peripheral wall and the received article. This allows airflow to reach the vented area of the article or the wrapper to provide a venting or cooling effect to the aerosol.

The ventilation chamber may be annular. The ventilation chamber may be a continuous annular chamber defined in a peripheral wall of the device housing. This enables the ventilation chamber to surround the entire wrapper or ventilation zone of the received article, thereby maximising the amount of overlap between the ventilation chamber and the ventilation zone of the received aerosol-generating article. The greater the amount of overlap, the greater the ventilation provided to the aerosol-generating article received in the device. In addition, the annular plenum can be simply and efficiently manufactured.

The ventilation chamber may have a square, rectangular or triangular longitudinal cross-section.

The ventilation chamber may be an annular portion (or sector) that partially surrounds the wrapper or ventilation zone of the received aerosol-generating article. The aerosol-generating device may comprise a plurality of ventilation chambers. Such a plurality of ventilation chambers may comprise a plurality of ventilation chambers arranged at different longitudinal positions or a plurality of ventilation chambers arranged at different circumferential positions.

The length of the plenum may be less than or equal to about 8 mm. The length of the plenum may be less than or equal to about 4 mm. The length of the plenum may be less than or equal to about 3 mm.

The length of the ventilation chamber may be greater than or equal to about 1 mm. The length of the plenum may be greater than or equal to about 2 mm. The length of the ventilation chamber may be greater than or equal to about 1 mm.

The length of the ventilation chamber may be between about 1mm and about 8 mm. The length of the plenum may be between about 2mm and about 4 mm. The length of the plenum may be between about 3mm and about 4 mm.

The length of the plenum may be at least about 2.5% of the length of the device lumen. The length of the plenum may be at least about 5% of the length of the device lumen. The length of the plenum may be at least about 7.5% of the length of the device lumen. The length of the plenum may be at least about 10% of the length of the device lumen.

The length of the ventilation chamber may be less than about 40% of the length of the device lumen. The length of the ventilation chamber may be less than about 30% of the length of the device lumen. The length of the ventilation chamber may be less than about 25% of the length of the device lumen. The length of the ventilation chamber may be less than about 20% of the length of the device lumen. The length of the ventilation chamber may be less than about 15% of the length of the device lumen.

The length of the ventilation chamber may be between about 2.5% and about 40% of the length of the device lumen. The length of the ventilation chamber may be between about 5% and about 30% of the length of the device lumen. The length of the ventilation chamber may be between about 7.5% and about 25% of the length of the device lumen.

By providing a relatively short or small ventilation chamber, a relatively short or small overlap between the aerosol-generating article and the ventilation chamber of the aerosol-generating device may be achieved. Thus, a more directional and localised portion of the aerosol-generating article is cooled when received within the device, and so the cooling effect from the cooling air entering the ventilation chamber may be more effective on this portion of the article.

The depth of the plenum is the radial distance the plenum extends into the peripheral wall of the device housing. The depth of the plenum may be less than or equal to about 3 mm. The depth of the plenum may be less than or equal to about 2 mm. The depth of the plenum may be less than or equal to about 1.5 mm.

The depth of the plenum may be greater than or equal to about 0.5 mm. The depth of the ventilation chamber may be greater than or equal to about 1 mm.

The depth of the ventilation chamber may be between about 0.5mm and about 3 mm. The depth of the ventilation chamber may be between about 1mm and about 2 mm.

The cross-sectional area of the plenum may be greater than or equal to about 5 square millimeters. The cross-sectional area of the plenum may be greater than or equal to about 20 square millimeters. The cross-sectional area of the plenum may be greater than or equal to about 50 square millimeters.

The cross-sectional area of the plenum may be less than or equal to about 275 square millimeters. The cross-sectional area of the plenum may be less than or equal to about 150 square millimeters.

The cross-sectional area of the plenum may be between about 5 square millimeters and about 275 square millimeters. The cross-sectional area of the plenum may be between about 20 square millimeters and about 150 square millimeters.

The thickness of a peripheral wall of the aerosol-generating device housing defining the device housing may be greater than or equal to about 1 mm. The thickness of the peripheral wall may be greater than or equal to about 2 mm. The thickness of the peripheral wall may be greater than or equal to about 3 mm.

The thickness of a peripheral wall of the aerosol-generating device housing defining the device housing may be less than or equal to about 10 mm. The thickness of the peripheral wall may be less than or equal to about 7.5 mm. The thickness of the peripheral wall may be less than or equal to about 5 mm.

The thickness of the peripheral wall of the aerosol-generating device housing defining the device housing may be between about 1mm and about 10 mm. The thickness of the peripheral wall may be between about 2mm and about 7.5 mm. The thickness of the peripheral wall may be between about 3mm and about 5 mm.

The depth of the plenum may be less than or equal to about 75% of the thickness of the peripheral wall. The depth of the ventilation chamber may be less than or equal to about 50% of the thickness of the peripheral wall. The depth of the plenum may be less than or equal to about 35% of the thickness of the peripheral wall.

The depth of the plenum may be greater than or equal to about 10% of the thickness of the peripheral wall. The depth of the plenum may be greater than or equal to about 20% of the thickness of the peripheral wall. The depth of the plenum may be greater than or equal to about 25% of the thickness of the peripheral wall.

The depth of the plenum may be between about 10% and about 75% of the thickness of the peripheral wall. The depth of the plenum may be between about 20% and about 50% of the thickness of the peripheral wall. The depth of the plenum may be between about 25% and about 35% of the thickness of the peripheral wall.

The aerosol-generating device may comprise an extractor for extracting an aerosol-generating article received in the aerosol-generating device, the extractor being configured to be movable within the device cavity.

The extractor is configured to expose the ventilation chamber when the extractor is in an operating position, the operating position being defined by the heater being in contact with an aerosol-forming substrate of the aerosol-generating article.

The extractor includes a container body configured to receive an aerosol-generating article. The container body (extractor body) of the extractor may include an end wall and a peripheral wall. The container body of the extractor includes an open end opposite the end wall through which the aerosol-generating article may be received. The aerosol-generating article is configured to abut the end wall once received within the extractor body. The peripheral wall of the container body may circumscribe the aerosol-generating article when the aerosol-generating article is received within the extractor. In such embodiments where an extractor is present, the peripheral wall of the extractor body may define a vent chamber. Alternatively, the peripheral wall of the device housing may define a ventilation chamber.

The extractor can be sized such that in the operating position, the container body extends between the first end of the plenum and the distal end of the device cavity. This enables the aerosol-generating article to be directly exposed to the ventilation chamber without the extractor body obscuring fluid communication between the ventilation chamber and the aerosol-generating article.

The extractor may be dimensioned such that, in the operative position, the container body extends between a mouth end of the device lumen and a distal end of the device lumen. In such embodiments, the extractor body may have a cut or cuts to allow the ventilation chamber to be exposed to the aerosol-generating article upon insertion. The extractor body and the device cavity together may be configured to ensure alignment with the vent chamber or chambers during use of the one or more cutouts. For example, the suction body may comprise a protrusion arranged to mate with a slot or groove located in a housing of the aerosol-generating device.

The aerosol-generating device may comprise an elongate heater arranged for insertion into the aerosol-generating article when the aerosol-generating article is received within the device cavity. An elongated heater may be disposed with the device lumen. The elongated heater may extend into the device cavity. Alternative heating means are discussed further below. However, in such embodiments where the heater extends into the device cavity, the extractor body comprises an aperture at the end wall for allowing the heater to extend into the aerosol-generating article. Such apertures may allow air to enter the interior of the extractor cavity so that air may flow through the rod of aerosol-forming substrate of the aerosol-generating article during use. Alternatively, additional apertures may be provided to allow air to enter the interior of the extractor chamber.

In some embodiments, the length of the extractor body can be less than the length of the device cavity. In such embodiments, the vent chamber may be defined by a portion of the device housing that does not enclose the peripheral wall of the extractor when the extractor is in the operating position (when the extractor abuts the distal end of the device lumen). This portion of the peripheral wall defines a ventilation chamber when the extractor is in the operating position. Effectively, the portion of the peripheral wall of the device housing may extend longitudinally beyond the extractor to define the ventilation chamber. The space or gap between the aerosol-generating article and the peripheral wall of the device housing defines a ventilation chamber.

The airflow path may be defined to enable fluid communication between an aerosol-forming substrate of an aerosol-generating article received within the device cavity and the exterior of the aerosol-generating device. The airflow path allows an aerosol to be formed when a user draws on an aerosol-generating article heated within the aerosol-generating device. Air from the air flow path may flow into the upstream end of the aerosol-generating article and through the aerosol-forming substrate of the article. Such an airflow path may be defined within the aerosol-generating device.

In embodiments where an extractor is provided, an airflow path may be defined between a peripheral wall of the aerosol-generating device housing and an outer surface of the extractor, wherein the ventilation chamber is in fluid communication with the airflow path.

In embodiments where no extractor is provided, the airflow path may be defined within the thickness of a peripheral wall of the aerosol-generating device housing. The airflow path may also be in fluid communication with the vent chamber.

There is also provided an aerosol-generating system comprising an aerosol-generating article and an aerosol-generating device as discussed above. An aerosol-generating article may comprise a rod of aerosol-forming substrate and a filter positioned downstream of the rod of aerosol-forming substrate. The aerosol-forming substrate rod and filter may be assembled within a wrapper. The aerosol-generating article may comprise a ventilation zone located on the wrapper. The aerosol-generating system is configured such that when the aerosol-generating article is received within the device cavity, the ventilation zone of the aerosol-generating article is located within the device cavity such that the ventilation chamber covers the ventilation zone of the aerosol-generating article.

As mentioned above, the ventilation chamber may be annular so as to surround the ventilation zone of the aerosol-generating article when the aerosol-generating article is received within the device.

By providing a ventilation chamber covering the ventilation zone from the aerosol-generating article, it is ensured that during use of the aerosol-generating system, the ventilation zone of the aerosol-generating article is covered by the housing of the aerosol-generating device and is not exposed to the exterior of the device.

In addition, by providing a ventilation chamber covering the ventilation zone of the article, it is also ensured that air or aerosol can flow between the ventilation zone of the article and the inner surface of the ventilation chamber defined in the peripheral wall. This means that the ventilation zone may function as it provides ventilation to the article during normal use without being obscured or blocked by the consumer.

The ventilation chamber may be configured to be in fluid communication with an exterior of the aerosol-generating device and a ventilation zone of the aerosol-generating article.

When the aerosol-generating article is received within the device cavity, the ventilation zone of the article is arranged to align with and be surrounded by a ventilation chamber defined within the device. This ensures that during normal use of the aerosol-generating system, the ventilation zone of the aerosol-generating article is covered by the housing of the aerosol-generating device such that the ventilation zone is not exposed to the exterior of the device. It is also ensured that air or aerosol can flow between the ventilation chamber of the device and the ventilation zone of the article. This means that the ventilation zone can function to provide ventilation to the article during use without being obscured or blocked by the mouth or fingers of the consumer.

Throughout this specification, the term "ventilation level" may be used to denote the volumetric ratio of airflow into the aerosol-generating article via the ventilation zone (ventilation airflow) to the sum of the aerosol airflow and the ventilation airflow. The greater the level of ventilation, the higher the dilution of the aerosol stream delivered to the consumer. The ventilation level is measured independently on the aerosol-generating article, i.e. without inserting the aerosol-generating article into a suitable aerosol-generating device adapted to heat the aerosol-forming substrate.

Aerosol-generating articles of the present disclosure may comprise a downstream section located downstream of the rod of aerosol-forming substrate. Such a downstream section may be considered to be a filter for an aerosol-generating article. The filter (or downstream section of the article) or the mouthpiece segment may comprise a plug of filtration material and a hollow tubular segment at a location between the aerosol-forming substrate rod and the mouthpiece segment. All three elements are longitudinally aligned. The rod of aerosol-forming substrate comprises at least an aerosol former. In some embodiments, aerosol-generating articles for use with the present invention may comprise an additional support element (or support section) arranged between and in longitudinal alignment with the aerosol-forming substrate rod and the hollow tubular section. In more detail, the support element (or support section) is preferably arranged immediately downstream of the rod and immediately upstream of the hollow tubular section. The support element or segment may be tubular.

The ventilation zone of the aerosol-generating article may be located at any position along the article. The ventilation zone may be located at a position downstream of the rod of aerosol-forming substrate. The ventilation zone may be located at a position along the hollow tubular section of the filter or mouthpiece section of the article. The ventilation zone may be located at a position along the plug of filter material of the filter of the article.

The filter of the aerosol-generating article may comprise a mouthpiece segment comprising a plug of filter material arranged downstream of a rod of aerosol-forming substrate; and a hollow tubular section located between the mouthpiece section and the rod of aerosol-forming substrate, wherein the ventilation zone is located at a position along the upstream half of the hollow tubular section.

The term "upstream half" refers to a region or portion of an element between the upstream end of the element and the midpoint of the element.

The aerosol-generating article may comprise a ventilation zone at a location along the hollow tubular section less than about 18 millimeters (mm) from the upstream end of the hollow tubular section. The distance between the vented zone and the upstream end of the hollow tubular section may be less than about 15 millimeters. Even more preferably, the distance between the vented zone and the upstream end of the hollow tubular section is less than about 10 millimeters.

Additionally, or alternatively, the distance between the vented zone and the upstream end of the hollow tubular section may be at least about 2 millimeters. The distance between the vented zone and the upstream end of the hollow tubular section may be at least about 4 millimeters. The distance between the vented zone and the upstream end of the hollow tubular section may be at least about 6 millimeters.

The ventilation zone may be disposed at a location along the hollow tubular segment at least about 2mm from the upstream end of the mouthpiece. Preferably, the ventilation zone is provided along the hollow tubular section at a location at least 4mm from the upstream end of the mouthpiece. Preferably, the ventilation zone is disposed at a location along the hollow tubular segment at least about 5mm from the upstream end of the mouthpiece. Even more preferably, the ventilation zone is provided at a location along the hollow tubular section at least 6mm from the upstream end of the mouthpiece.

When the mixture of air and aerosol particles flowing through the aerosol-generating article reaches the ventilation zone, external air drawn into the hollow tubular section via the ventilation zone mixes with the aerosol. This rapidly reduces the temperature of the aerosol mixture while partially diluting the mixture of air and aerosol particles. By providing a ventilation zone falling within the above ranges at a distance from the upstream end of the mouthpiece segment, the cooling chamber is effectively provided immediately upstream of the mouthpiece, wherein nucleation and growth of aerosol particles is advantageously promoted. Thus, the dilution effect of the ventilation air into the hollow tubular section is at least partially counteracted, which advantageously enables to provide a consumer-satisfactory aerosol delivery level.

The ventilation zone may be disposed along the hollow tubular section at a distance of at least about 10mm from the downstream end of the mouthpiece section. The ventilation zone may be disposed along the hollow tubular section at a distance of at least about 12 mm from the downstream end of the mouthpiece section. The ventilation zone may be disposed along the hollow tubular section at a distance of at least about 15mm from the downstream end of the mouthpiece section. This is advantageous as it ensures that the ventilation zone is not blocked by the consumer's lip during use.

In some embodiments, the ventilation zone is disposed along the hollow tubular section at a location from about 10mm to about 25mm from the downstream end of the mouthpiece section, more preferably from about 12 mm to about 20mm from the downstream end of the mouthpiece section. In an exemplary embodiment, the ventilation zone is disposed about 18 millimeters from the downstream end of the mouthpiece section along the hollow tubular section. In another exemplary embodiment, the ventilation zone is disposed about 13 millimeters from the downstream end of the mouthpiece section along the hollow tubular section.

Without wishing to be bound by theory, it has been found that the temperature drop caused by the cooler, external air entering the hollow tubular section via the ventilation zone, may have a beneficial effect on the nucleation and growth of aerosol particles.

In this scenario, which may be further complicated by coalescence phenomena, the temperature and rate of cooling play a key role in determining how the system responds. Generally, different cooling rates can result in significantly different time behaviors associated with liquid phase (droplet) formation, as the nucleation process is generally non-linear. Without wishing to be bound by theory, it is hypothesized that cooling may result in a rapid increase in the number concentration of droplets, followed by a strong, transient increase in this growth (nucleation burst). This nucleation burst appears to be more pronounced at lower temperatures. Furthermore, it appears that a higher cooling rate may be beneficial to initiate nucleation earlier. In contrast, a decrease in the cooling rate appears to have a favorable effect on the final size that the aerosol droplets eventually reach.

Thus, the rapid cooling caused by the external air entering the hollow tubular section via the ventilation zone may advantageously be used to promote the nucleation and growth of aerosol droplets. At the same time, however, the entry of outside air into the hollow tubular section has the direct disadvantage of diluting the aerosol stream delivered to the consumer.

In addition, it has been found that in aerosol-generating articles for use in the present invention, the cooling and dilution effect caused by the ingress of ventilation air at a location along the conduit defined by the hollow tubular section described above has a surprisingly reduced effect on the generation and delivery of phenolic-containing materials.

The ventilation zone may comprise one or more rows of apertures or perforations extending through the wrapper of the aerosol-generating article. The apertures or perforations of the ventilation zone may extend through the filter of the aerosol-generating article.

The ventilation zone may be located at a position along the rod of aerosol-forming substrate. The ventilation zone may be located at a position downstream of the rod of aerosol-forming substrate. The ventilation zone may be located at a position along the hollow tubular section. The ventilation zone may be located at a position along the support section. The ventilation zone may be located at a position along the mouthpiece section. Depending on where the ventilation zone is located, the aperture of the ventilation zone may extend through the hollow tubular section, the support section or the mouthpiece section.

The ventilation zone may be positioned along the hollow tubular section, and the apertures or perforations of the ventilation zone may extend through the peripheral wall of the hollow tubular section. This is understood to be advantageous because aerosol nucleation may be further enhanced by concentrating the cooling effect created by ventilation on the short portion of the cavity defined by the hollow tubular section. This is because a faster and more intense cooling of the flow of volatile substances from the aerosol-forming substrate is expected to be particularly advantageous for the formation of new nuclei of aerosol particles.

The ventilation zone may comprise only one row of apertures or perforations. A row of apertures or perforations may comprise between 8 and 30 apertures or perforations. The ventilation zone may surround the aerosol-generating article. The ventilation zone may surround the rod of aerosol-forming substrate. The ventilation zone may surround the hollow tubular section. The ventilation zone may surround the support section. The ventilation zone may surround the mouthpiece section. The ventilation perforations (or apertures) may be of uniform size. Alternatively, the size of the ventilation perforations may be different. By varying the number and size of the ventilation perforations, the amount of outside air entering the hollow tubular section can be adjusted as the consumer draws in the mouthpiece of the aerosol-generating article during use. Thus, the ventilation level of the aerosol-generating article may advantageously be adjusted.

The ventilation perforations may be formed using any suitable technique, for example by laser techniques, mechanical perforation of a hollow tubular section that is part of the aerosol-generating article, or pre-perforation before the hollow tubular section is combined with other elements to form the aerosol-generating article. Preferably, the vent perforations are formed by in-line laser perforation.

In aerosol-generating articles for use in the present invention, the total Resistance To Draw (RTD) of the article is substantially dependent on the RTD of the rod of aerosol-forming substrate and the RTD of the mouth piece section of the filter, as the hollow tubular section is substantially empty and therefore contributes substantially only to a certain extent to the total RTD. In practice, the hollow tubular section may be adapted to produce a range of about 0mm H ₂ O (about 0Pa) to about 20mm H ₂ RTD of O (about 200 Pa). The hollow tubular section may be adapted to produce between about 0mm H ₂ O (about 0Pa) to about 10mm H ₂ RTD between O (about 100 Pa).

The aerosol-generating article may have an H of less than about 90 mm ₂ Total RTD of O (about 900 Pa). The aerosol generating article may have a total RTD of less than about 80 millimeters H2O (about 800 Pa). The aerosol-generating article may have a H of less than about 70 mm ₂ Total RTD of O (about 700 Pa).

Additionally or alternatively, the aerosol-generating article may have a H of at least about 30mm ₂ Total RTD of O (about 300 Pa). The aerosol-generating article may have a H of at least about 40mm ₂ Total RTD of O (about 400 Pa). The aerosol-generating article may have a H of at least about 50mm ₂ Total RTD of O (about 500 Pa).

The RTD of the aerosol-generating article may be assessed as the negative pressure that must be applied to the downstream end of the mouthpiece under the test conditions defined in ISO 3402 in order to maintain a steady volumetric flow of air of 17.5ml/s through the mouthpiece. The RTD values listed above are intended to be measured on the aerosol-generating article alone (i.e. prior to insertion of the article into the aerosol-generating device) without blocking the perforations of the ventilation zone.

The distance between the ventilation zone and the upstream end of the aerosol-generating article may be less than about 50 mm. The distance between the ventilation zone and the upstream end of the aerosol-generating article may be less than about 45 mm. The distance between the ventilation zone and the upstream end of the aerosol-generating article may be less than about 40 mm.

The distance between the ventilation zone and the upstream end of the aerosol-generating article may be at least about 12 mm. The distance between the ventilation zone and the upstream end of the aerosol-generating article may be at least about 15 mm. The distance between the ventilation zone and the upstream end of the aerosol-generating article may be at least about 20 mm. In some embodiments, the distance between the ventilation zone and the upstream end of the aerosol-generating article may be at least about 25 mm.

The distance between the ventilation zone and the downstream end of the rod of aerosol-forming substrate may be at least about 2 mm. The distance between the ventilation zone and the downstream end of the rod of aerosol-forming substrate may be at least about 5 mm. The distance between the ventilation zone and the downstream end of the rod of aerosol-forming substrate may be at least about 10 mm. In some embodiments, the distance between the ventilation zone and the downstream end of the rod of aerosol-forming substrate may be at least about 15 millimetres.

The distance between the ventilation zone and the downstream end of the rod of aerosol-forming substrate may be less than about 35 mm. The distance between the ventilation zone and the downstream end of the rod of aerosol-forming substrate may be less than about 30 mm. The distance between the ventilation zone and the downstream end of the rod of aerosol-forming substrate may be less than about 25 mm.

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

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

Preferably, the rod of aerosol-generating substrate has a substantially uniform cross-section along the length of the rod. Particularly preferably, the aerosol-generating substrate rod has a substantially circular cross-section.

In a preferred embodiment, the aerosol-forming substrate comprises one or more agglomerated sheets of homogenised tobacco material. Preferably, one or more sheets of homogenised 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 for the homogenized tobacco material of the present invention may include a plurality of spaced-apart indentations, protrusions, perforations, or a combination thereof. According to a particularly preferred embodiment of the invention, the aerosol-forming substrate rod comprises a gathered crimped sheet of homogenised 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 homogenised tobacco material has a plurality of ridges or corrugations that are substantially parallel to the cylindrical axis of the rod according to the invention. This advantageously promotes the gathering of the crimped sheet of homogenised tobacco material to form a rod. However, it will be appreciated that the crimped sheet of homogenised tobacco material for use in the present invention may alternatively or additionally have a plurality of substantially parallel ridges or corrugations that are disposed at acute or obtuse angles to the cylindrical axis of the rod. The sheet of homogenised tobacco material for use 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 homogenised tobacco material for use in the manufacture of rods for use in aerosol-generating articles for use with 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 homogenised tobacco material for use in the present invention may have a tobacco content of at least about 40 wt% by dry weight, more preferably at least about 60 wt% by dry weight, more preferably at least about 70 wt% by dry weight, most preferably at least about 90 wt% by dry weight.

The sheet or web of homogenised tobacco material for use in the aerosol-forming substrate may comprise one or more intrinsic binders, i.e. tobacco intrinsic binders, one or more extrinsic binders, i.e. tobacco extrinsic binders, or a combination thereof, to aid in the agglomeration of the particulate tobacco. Alternatively or additionally, the sheet of homogenised tobacco material for use in the aerosol-forming 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 homogenised tobacco material for use in aerosol-forming 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 fibers for inclusion in a sheet or web of homogenised tobacco material for an aerosol-forming 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 homogenised tobacco material for use in the aerosol-forming substrate, the non-tobacco fibres may be treated by suitable methods known in the art including, but not limited to: mechanically pulping; refining; chemical pulping; bleaching; sulfate pulping; and combinations thereof.

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

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

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

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

The sheet or web of homogenised tobacco for use 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 homogenised tobacco material for use in an aerosol-generating article is formed from a slurry comprising particulate tobacco, guar gum, cellulosic fibres and glycerol by a casting process.

Alternative arrangements of homogenised 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 homogenised tobacco material, a plurality of elongate tubular members formed by winding a rod of homogenised tobacco material about its longitudinal axis or the like.

As a further alternative, the aerosol-forming substrate rod may comprise a sheet of non-tobacco based, nicotine-containing material, for example a sorbent 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 aerosol-forming substrate rod may comprise non-tobacco plant material, for example aromatic non-tobacco plant material.

The aerosol-forming substrate is surrounded 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.

The mouthpiece segment comprises a plug of filter material capable of removing a particulate component, a gaseous component, or a combination. Suitable filter materials are known in the art and include, but are not limited to: fibrous filter materials such as, for example, cellulose acetate tow, viscose, Polyhydroxyalkanoate (PHA) fibers, polylactic acid (PLA) fibers, and paper; adsorbents such as, for example, activated alumina, zeolites, molecular sieves, and silica gel; and combinations thereof. In addition, the plug 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. In some embodiments, the mouthpiece may further comprise a mouth end recess downstream of the plug of filter material. For example, the mouthpiece may comprise a hollow tube longitudinally aligned with and arranged immediately downstream of the plug of filter material, the hollow tube forming a cavity at the mouth end, the cavity being open to the external environment at the downstream end of the mouthpiece and aerosol-generating article.

The length of the mouthpiece is preferably at least about 4mm, more preferably at least about 6mm, even more preferably at least about 8 mm. Additionally or alternatively, the length of the mouthpiece is preferably less than 25mm, more preferably less than 20mm, even more preferably less than 15 mm. In some preferred embodiments, the mouthpiece has a length of about 4mm to about 25mm, more preferably about 6mm to about 20 mm. The mouthpiece may be about 7 mm in length. The mouthpiece may be about 12 mm in length.

The length of the hollow tubular section is preferably at least about 10 mm. More preferably, the hollow tubular section has a length of at least about 15 millimeters. Additionally, or alternatively, the length of the hollow tubular section is preferably less than about 30 millimeters. More preferably, the hollow tubular section has a length of less than about 25 millimeters. Even more preferably, the length of the hollow tubular section is less than about 20 millimeters. In some preferred embodiments, the hollow tubular section has a length of about 10mm to about 30mm, more preferably about 12 mm to about 25mm, even more preferably about 15mm to about 20 mm. For example, in a particularly preferred embodiment, the length of the hollow tubular section is about 18 millimeters. In another particularly preferred embodiment, the length of the hollow tubular section is about 13 mm.

The peripheral wall of the hollow tubular section has a thickness of less than about 1.5 millimeters. Preferably, the thickness of the peripheral wall of the hollow tubular section is less than about 1250 microns, more preferably less than about 1000 microns, even more preferably less than about 900 microns. In a particularly preferred embodiment, the peripheral wall of the hollow tubular section has a thickness of less than about 800 microns.

Additionally, or alternatively, the peripheral wall of the hollow tubular section has a thickness of at least about 100 microns. Preferably, the thickness of the peripheral wall of the hollow tubular section is at least about 200 microns.

The overall length of the aerosol-generating article for use with the present invention is preferably at least about 40 mm. Additionally or alternatively, the total length of the aerosol-generating article for use with the present invention is preferably less than about 70 mm, more preferably less than about 60 mm, even more preferably less than about 50 mm. In a preferred embodiment, the aerosol-generating article has an overall length of between about 40mm and about 70 mm. In an exemplary embodiment, the total length of the aerosol-generating article is about 45 millimeters.

The support element (or segment) may have a length of between about 5 millimeters and about 15 millimeters. In a preferred embodiment, the support element has a length of about 8 millimeters.

The heater may comprise an elongate heating element configured to penetrate the aerosol-forming substrate strip when the aerosol-generating article is received within the aerosol-generating device.

The heater may be any suitable type of heater. The heater may internally heat the aerosol-generating article. Alternatively, the heater may heat the aerosol-generating article externally. Such an external heater may surround the aerosol-generating article when inserted or received in the aerosol-generating device.

In some embodiments, the heater is arranged to heat an outer surface of the aerosol-forming substrate. In some embodiments, the heater is arranged to be inserted into the aerosol-forming substrate when the aerosol-forming substrate is received within the cavity. A heater may be positioned within the cavity. The heater may extend into the cavity. The heater may be an elongate heater. The elongate heater may be blade shaped. The elongated heater may be pin-shaped. The elongate heater may be tapered. In some embodiments, the aerosol-generating device comprises an elongate heater arranged for insertion into the aerosol-generating article when the aerosol-generating article is received within the cavity.

The heater may comprise at least one heating element. The at least one heating element may be any suitable type of heating element. In some embodiments, the device comprises only one heating element. In some embodiments, the device comprises a plurality of heating elements.

The heater may comprise at least one resistive heating element. Preferably, the heater comprises a plurality of resistive heating elements. Preferably, the resistive heating elements are electrically connected in a parallel arrangement. Advantageously, providing a plurality of resistive heating elements electrically connected in a parallel arrangement may facilitate delivery of desired power to the heater while reducing or minimizing the voltage required to provide the desired power. Advantageously, reducing or minimizing the voltage required to operate the heater may facilitate reducing or minimizing the physical size of the power supply.

Suitable materials for forming the at least one resistive heating element include, but are not limited to: semiconductors such as doped ceramics, electrically "conductive" ceramics (e.g., molybdenum disilicide), carbon, graphite, metals, metal alloys, and composites made of ceramic and metallic materials. Such composite materials may include doped or undoped ceramics. Examples of suitable doped ceramics include doped silicon carbide. Examples of suitable metals include titanium, zirconium, tantalum, and platinum group metals. Examples of suitable metal alloys include stainless steel, alloys containing nickel, cobalt, chromium, aluminum-titanium-zirconium, hafnium, niobium, molybdenum, tantalum, tungsten, tin, gallium, manganese, and iron, and superalloys based on nickel, iron, cobalt, stainless steel, titanium alloys (Timetal), and iron-manganese-aluminum based alloys.

In some embodiments, at least one resistive heating element comprises one or more stamped portions of resistive material (such as stainless steel). Alternatively, the at least one resistive heating element may comprise heating wires or filaments, such as Ni-Cr (nickel-chromium), platinum, tungsten or alloy wires.

In some embodiments, the at least one heating element comprises an electrically insulating substrate, wherein the at least one resistive heating element is disposed on the electrically insulating substrate.

The electrically insulating matrix may comprise any suitable material. For example, the electrically insulating matrix may comprise one or more of: paper, glass, ceramic, anodized metal, coated metal, and polyimide. The ceramic may include mica, alumina (Al2O3), or zirconia (ZrO 2). Preferably, the electrically insulating matrix has a thermal conductivity of less than or equal to about 40 watts/meter-kelvin, preferably less than or equal to about 20 watts/meter-kelvin, and ideally less than or equal to about 2 watts/meter-kelvin.

The heater may comprise a heating element comprising a rigid electrically insulating substrate having one or more electrically conductive tracks or wires disposed on a surface thereof. The electrically insulating substrate may be of a size and shape to allow it to be inserted directly into the aerosol-forming substrate. If the electrically insulating matrix is not sufficiently rigid, the heating element may comprise further stiffening means. An electrical current may be passed through one or more electrically conductive traces to heat the heating element and the aerosol-forming substrate.

In some embodiments, the heater comprises an induction heating device. The induction heating device may include an inductor coil and a power supply configured to supply a high-frequency oscillating current to the inductor coil. As used herein, the term "high frequency oscillating current" means an oscillating current with a frequency between 500kHz and 30 MHz. Advantageously, the heater may comprise a DC/AC inverter for converting DC current supplied by a DC power source into alternating current. The inductor coil may be arranged to generate a high frequency oscillating electromagnetic field upon receiving a high frequency oscillating current from the power supply. The inductor coil may be arranged to generate a high frequency oscillating electromagnetic field in the device cavity. In some embodiments, the inductor coil may substantially surround the device cavity. The inductor coil may extend at least partially along the length of the device lumen.

The heater may comprise an induction heating element. The induction heating element may be a susceptor element. As used herein, the term "susceptor element" refers to an element comprising a material capable of converting electromagnetic energy into heat. When the susceptor element is positioned in the alternating electromagnetic field, the susceptor is heated. The heating of the susceptor element may be the result of at least one of hysteresis losses and eddy currents induced in the susceptor, depending on the electrical and magnetic properties of the susceptor material.

The susceptor element may be arranged such that when the aerosol-generating article is received in a cavity of the aerosol-generating device, the oscillating electromagnetic field generated by the inductor coil induces an electric current in the susceptor element, causing the susceptor element to heat up. In these embodiments, the aerosol-generating device is preferably capable of generating a fluctuating electromagnetic field having a magnetic field strength (hfieldstrength) of between 1 and 5 kilo-amperes per meter (kA/m), preferably between 2 and 3kA/m, for example about 2.5 kA/m. Preferably, the electrically operated aerosol-generating device is capable of generating a fluctuating electromagnetic field having a frequency between 1MHz and 30MHz, for example between 1MHz and 10MHz, for example between 5MHz and 7 MHz.

In some embodiments, the susceptor element is located in the aerosol-generating article. In these embodiments, the susceptor element is preferably positioned in contact with the aerosol-forming substrate. The susceptor element may be located in the aerosol-forming substrate.

In some embodiments, the susceptor element is located in the aerosol-generating device. In these embodiments, the susceptor element may be located in the cavity. The aerosol-generating device may comprise only one susceptor element. The aerosol-generating device may comprise a plurality of susceptor elements.

In some embodiments, the susceptor element is arranged to heat an outer surface of the aerosol-forming substrate. In some embodiments, the susceptor element is arranged to be inserted into the aerosol-forming substrate when the aerosol-forming substrate is received within the cavity.

The susceptor element may comprise any suitable material. The susceptor element may be formed from any material that is capable of being inductively heated to a temperature sufficient to release the volatile compounds from the aerosol-forming substrate. Suitable materials for the elongate susceptor element include graphite, molybdenum, silicon carbide, stainless steel, niobium, aluminum, nickel-containing compounds, titanium, and composites of metallic materials. Some susceptor elements include metal or carbon. Advantageously, the susceptor element may comprise or consist of a ferromagnetic material, such as ferritic iron, ferromagnetic alloys (e.g. ferromagnetic steel or stainless steel), ferromagnetic particles and ferrites. Suitable susceptor elements may be or include aluminum. The susceptor element preferably comprises greater than about 5%, preferably greater than about 20%, more preferably greater than about 50% or greater than about 90% ferromagnetic or paramagnetic material. Some of the elongated susceptor elements may be heated to a temperature in excess of about 250 degrees celsius.

The susceptor element may comprise a non-metallic core on which a metallic layer is provided. For example, the susceptor element may comprise metal traces formed on the outer surface of a ceramic core or substrate.

In some embodiments, the aerosol-generating system comprises at least one resistive heating element and at least one inductive heating element. In some embodiments, the aerosol-generating system comprises a combination of a resistive heating element and an inductive heating element.

The aerosol-generating device comprises a power source. The power supply may be a DC power supply. In some embodiments, the power source is a battery. The power source may be a nickel metal hydride battery, a nickel cadmium battery, or a lithium based battery, such as a lithium cobalt battery, a lithium iron phosphate battery, or a lithium polymer battery. However, in some embodiments, the power supply may be another form of charge storage device, such as a capacitor. The power source may require recharging and may have a capacity that allows storage of energy sufficient for one or more user operations, e.g., one or more aerosol-generating experiences. For example, the power source may have sufficient capacity to allow continuous heating of the aerosol-forming substrate for a period of approximately six minutes, corresponding to the typical time taken to smoke a conventional cigarette, or for a period of more than six minutes. In another example, the power source may have sufficient capacity to allow a predetermined number or discrete pumping or activation of the heater.

Drawings

Specific embodiments will now be described with reference to the drawings, in which:

figure 1 is a schematic cross-sectional view of a comparative aerosol-generating device and a comparative aerosol-generating system; and

figure 2 is a schematic cross-sectional view of an embodiment of an aerosol-generating system.

Detailed Description

Fig. 1 shows an aerosol-generating system 100 comprising a comparative aerosol-generating device 10 and an aerosol-generating article 1. The aerosol-generating device 10 comprises a housing 4 extending between a mouth end 2 and a distal end (not shown). The housing 4 comprises a peripheral wall 6. The peripheral wall 6 defines a device cavity for receiving the aerosol-generating article 1. The extractor 8 is located within a device cavity defined by the peripheral wall 6 and is configured to receive and extract the aerosol-generating article 1 from the device cavity. Extractor 8 comprises a body having an open end and a closed end. The closed end of the body of the extractor 8 is defined by an end wall. The device lumen is further defined by a closed distal end and an open mouth end. The mouth end of the device cavity is located at the mouth end of the aerosol-generating device 10. The aerosol-generating article 1 is configured to be received through the mouth end of the device cavity and is configured to abut the closed end of the device cavity or the closed end of the extractor 8. The closed end of the extractor 8 is configured to substantially abut or be proximate to the closed end of the device cavity.

An airflow path 32 is defined around the outer surface of the extractor 8 and is defined between the peripheral wall 6 of the aerosol-generating device housing 4 and the outer surface of the extractor 8. Air is allowed to enter extractor 8 through an aperture (not shown) at the closed end of the body of extractor 8. This enables air to flow through the aerosol-generating substrate rod 12 and further downstream through the remainder of the aerosol-generating article 1 when a user generates a puff at the mouth end of the aerosol-generating article 1.

The aerosol-generating device 10 further comprises a heater (not shown) and a power supply (not shown) for supplying power to the heater. A controller (not shown) is also provided to control this supply of power to the heater. The heater is configured to heat the aerosol-generating article 1 during use when the aerosol-generating article 1 is received within the device 10.

The aerosol-generating article 1 comprises a rod of aerosol-forming substrate 12, a hollow support segment 14, a hollow tubular segment 16 and a mouthpiece segment 18. These four elements are arranged in end-to-end, longitudinally aligned fashion and are surrounded by a wrapper 22 to form the aerosol-generating article 1. The aerosol-generating article 1 shown in figure 1 is particularly suitable for use with an electrically operated aerosol-generating device 1 comprising a heater for heating a rod 12 of aerosol-forming substrate.

The rod of aerosol-forming substrate 12 has a length of about 12 mm and a diameter of about 7 mm. The rod 12 is cylindrical and has a substantially circular cross-section. The rod 12 comprises a sheet of gathered homogenised tobacco material. The hollow cellulose acetate tube (hollow support section) 14 has a length of about 8 millimeters and the thickness of the tube wall is about 1.75 millimeters.

The mouthpiece section 18 comprises a plug of cellulose acetate tow of 8 denier per filament and has a length of about 12 millimeters.

The hollow tubular section 16 is provided as a cylindrical tube having a length of about 13 millimeters and a tube wall thickness of about 175 micrometers.

The aerosol-generating article 1 comprises a ventilation zone 26 disposed at least about 5mm from the upstream end of the mouthpiece section 18. Thus, the ventilation zone 26 is at about 18 mm from the downstream end of the aerosol-generating article 1. Accordingly, the vented zone 26 is at least about 21 millimeters from the downstream end of the rod 12. The ventilation zone 26 includes a series or row of perforations that extend through the wrapper 22.

As shown in figure 1, the ventilation zone 26 of the aerosol-generating article 1 is exposed when the aerosol-generating article 1 is received within a device cavity.

Fig. 2 shows an embodiment of an aerosol-generating system 200 comprising an aerosol-generating device 20 and an aerosol-generating article 1. The aerosol-generating device 20 comprises an extractor 8.

The aerosol-generating device 20 further comprises a ventilation chamber 28 configured to surround the ventilation zone 26 of the aerosol-generating article 1 when the aerosol-generating article is received within the aerosol-generating device 20. The device lumen has a total length of 30mm and the ventilation chamber 28 has a length of 5 mm. The ventilation chamber 28 has a rectangular longitudinal sectional shape. The ventilation chamber 28 is also annular, such that the ventilation chamber 28 extends around the entire inner circumference of the peripheral wall 6. During use, the ventilation chamber 28 surrounds the periphery of the aerosol-generating article 1.

The plenum 28 is configured to be in fluid communication with the vented zone 26 of the article 1 and the exterior of the aerosol-generating device 20 via the mouth end of the device 10. The plenum 28 is also configured to be in fluid communication with an airflow path 32 defined around the extractor 8. As shown in fig. 2, a ventilation chamber 28 is defined within the thickness of the peripheral wall 6.

As shown in fig. 2, the ventilation chamber 28 is located away from the mouth end 2 of the aerosol-generating device 20. The ventilation chamber 28 is not in direct fluid communication with the exterior of the aerosol-generating device 20. The ventilation chamber 28 is in fluid communication with the exterior of the aerosol-generating device 20 through the plurality of chamber inlets 24. Each chamber inlet 24 extends between the plenum 28 and the mouth end 2 of the aerosol-generating device 20 to establish fluid communication between the plenum 28 and the mouth end 2 of the aerosol-generating device 20.

Each chamber inlet 24 has a circular cross-section. The diameter of each chamber inlet 24 is substantially less than the depth (i.e., radial depth) of the plenum chamber 28. As shown in fig. 2, the depth of the plenum 28 is five times the diameter of the chamber inlet 24.

During use of the aerosol-generating system 200 described above, the ventilation zone 26 of the aerosol-generating article 1 cannot be directly blocked by a consumer when the aerosol-generating article 1 is received within the cavity of the aerosol-generating device 20. This is a result of the overlap of the peripheral wall 6 with the ventilation zone 26.

Claims

1. An aerosol-generating device configured to receive an aerosol-generating article, wherein the aerosol-generating device has a distal end and a mouth end, the aerosol-generating device comprising:

a housing comprising a peripheral wall defining a device cavity for removably receiving the aerosol-generating article at the mouth end of the device; and

a heater for heating the aerosol-generating article when the aerosol-generating article is received within the device cavity;

wherein the housing comprises a ventilation chamber defined within the peripheral wall and configured to be in fluid communication with an exterior of the aerosol-generating device and an aerosol-generating article received within the device cavity,

wherein the ventilation chamber is configured to be in fluid communication with the exterior of the aerosol-generating device through a chamber inlet defined in the housing, the chamber inlet having a smaller cross-sectional area than the ventilation chamber and extending between the ventilation chamber and the mouth end of the aerosol-generating device,

further wherein the length of the ventilation chamber is less than or equal to 8 mm.

2. An aerosol-generating device according to claim 1, wherein the ventilation chamber is located at a longitudinal position facing away from the mouth end of the aerosol-generating device.

3. An aerosol-generating device according to any preceding claim, wherein the chamber inlet is between about 1mm and about 6mm in length.

4. An aerosol-generating device according to any preceding claim, wherein the cross-sectional area of the chamber inlet is less than or equal to 50% of the cross-sectional area of the ventilation chamber.

5. An aerosol-generating device according to any preceding claim, wherein the thickness of the portion of the peripheral wall defining the ventilation chamber is different to the thickness of a different portion of the peripheral wall.

6. An aerosol-generating device according to claim 5, wherein the portion of the peripheral wall defining the ventilation chamber has a thickness that is less than a thickness of a different portion of the peripheral wall.

7. An aerosol-generating device according to claim 6, wherein the thickness of the portion of the peripheral wall defining the ventilation chamber varies along the longitudinal direction.

8. An aerosol-generating device according to any preceding claim, wherein the ventilation chamber is annular.

9. An aerosol-generating device according to any preceding claim, wherein the aerosol-generating device comprises an extractor for extracting the aerosol-generating article received in the aerosol-generating device, the extractor being configured to be movable within the device cavity.

10. An aerosol-generating device according to claim 9, wherein the extractor is configured to expose the ventilation chamber when the extractor is in an operative position defined by the heater being in contact with the aerosol-forming substrate of the aerosol-generating article.

11. An aerosol-generating device according to claim 9 or 10, wherein an airflow path is defined between the peripheral wall of the aerosol-generating device housing and an outer surface of the extractor, wherein the ventilation chamber is in fluid communication with the airflow path.

12. An aerosol-generating system, the aerosol-generating system comprising:

an aerosol-generating article comprising:

a rod of aerosol-forming substrate; and

a filter positioned downstream of the aerosol-forming substrate rod;

wherein the rod of aerosol-forming substrate and the filter are assembled within a wrapper, the aerosol-generating article comprising a ventilation zone on the wrapper, the ventilation zone comprising a plurality of apertures extending through the wrapper; and

an aerosol-generating device according to any preceding claim;

wherein the aerosol-generating system is configured such that when the aerosol-generating article is received within the device cavity, the ventilation zone of the aerosol-generating article is located within the device cavity such that the ventilation chamber covers the ventilation zone of the aerosol-generating article.

13. An aerosol-generating system according to claim 12, wherein the filter of the aerosol-generating article comprises:

a mouthpiece segment comprising a plug of filter material arranged downstream of the rod of aerosol-forming substrate; and

a hollow tubular section located between the mouthpiece section and the aerosol-forming substrate rod,

wherein the ventilation zone is located at a position along the upstream half of the hollow tubular section.

14. An aerosol-generating system according to claim 12 or 13, wherein the heater comprises an elongate heating element configured to penetrate the aerosol-forming substrate rod when the aerosol-generating article is received within the aerosol-generating device.